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1096
Shipyard
DAEWOO HEAVY INDUSTRIES LTD
Project No.
2/0702102LMW1
2011-08-18 Project No: 2/0702102LMW1
Valid for: 62507582
Order Information
Project No....................................................................2/0702102LMW1
IMO......................................................................................... L9086071
Hull No............................................................................................ 1096
Ship name.......................................................................... TRANS BAY
Shipyard......................................DAEWOO HEAVY INDUSTRIES LTD
Ship owner............................................................ Bulk Transloading As
Certificate for Crane.........................................................................ABS
Certificate for Foundation................................................................ ABS
Equipment Name................................................................. K3028-4HD
Manufacturing No. + Position..............................................62507582 3
Mechanical Specification (Collection list)..............................490 6135 /-
Hydraulic Specification (Crane Specification)......................490 6091 /A
Electrical Specification........................................................ 490 6083 /D
Slewing Specification................................... 490 6136 and 6137-802 /A
Order Specification.............................................................. 490 5961 /F
Delivered Manuals..........................................................................3 pcs
Issue Date............................................................................ 2011-08-18
1 GENERAL
1.000.2 E SAFETY INSTRUCTIONS
1.005 E PREFACE
1.009 E GENERAL INSTRUCTIONS. CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E CONVERSION FACTORS
1.518.3 ED HYDRAULIC AND ELECTRIC SYMBOLS
2 TECHNICAL DESCRIPTION
2/07021.02LMW-1 TECHNICAL DATA
2.007.82 E TECHNICAL DESCRIPTION
3 FUNCTION
3.110.107 E HYDRAULIC FUNCTION
3.131.27 E STARTING AND STOPPING. ELECTRIC SAFETY FUNCTIONS. K-CRANES
3.142.24 E CRANE CONTROL SYSTEM CC2000 TYPE K. 4-ROPE GRAB CRANE
3.155.4 E THERMOSTATIC CONTROLLED VENTILATION FANS
4 OPERATION
PM40 1852-E00 CREW CHECKLIST
PM40 5500-E00 OPERATING INSTRUCTION
PM40 6100-E00 AIR CONDITIONING. OPERATING INSTRUCTION
PM40 6840-E00 CONTROLS AND INDICATORS. CRANE AND ECCENTER PLATFORM
PM40 6446-E00 OPERATING INSTRUCTION
PM40 6454-E00 OPERATING INSTRUCTION. CRANE/ECCENTER PLATFORM
PM40 6713-E00 OPERATING INFORMATION - MacHEAVYVISOR 2.0
PM41 0001-E EMERGENCY ESCAPE INSTRUCTIONS
PM46 2517-E00 PARKING OF ECCENTRIC PLATFORM. PARKING LOCK
4.620.26 E PARKING THE CRANE. SEA STOWING. GENERAL INSTRUCTION
5 MAINTENANCE
5.005.61 E MAINTENANCE CHART
5.006.2 E AIR CONDITIONING. MAINTENANCE / TROUBLE-SHOOTING /SERVICE
5.006.12 E VENTILATION WITH FILTER
5.018 E INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
PM51 1718-E00 LUBRICATING CHART
PM51 1722-E00 LUBRICATING CHART. ECCENTRIC PLATFORM
5.301.8 E FILTERS
5.301.9 E FILTER WITH INDICATOR. ECCENTER PLATFORM
5.301.10 E FILTER ON OIL TANK. ECCENTRIC PLATFORM
5.301.14 E FILTER WITH INDICATOR IN THE WINCH GEAR COOLING SYSTEM
5.301.17 E FILTER WITH INDICATOR IN THE OIL CIRCULATION SLEWING GEARS
5.302.17 E HYDRAULIC OIL TANK
5.302.18 E HYDRAULIC OIL TANK IN ECCENTRIC PLATFORM
5.421.46 E LUBRICANTS FOR DECK MACHINERY
5.315 E SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM
6 SERVICE
7 EXTRA EQUIPMENT
7.075.4 E MacHEAVYVISOR. RELEASE 2.0
7.076.1 E SAFE CONNECTION/DISCONNECTION OF CABIN DISPLAY
7.076.2 E USER MANUAL DISPLAY. CC PILOT XS
9 SPARE PARTS
See separate table of contents
Safety Instructions
1. Safety Functions
Regular Care and Control (Maintenance)
a. Maneuvring functions:
This manual contains checklists for regular care and
1. All the cranes working functions are stopped
control of crane equipment, wire ropes and hydraulic
and the brakes will automatically be activated
filters. These checklists routine contain inspections
when the emergency stop button is pressed.
and maintenance regularly prescribed for safe func-
The button is loacated in cabin. This action ac-
tion, e.g.:
tivates safety stops and automatic lock posi-
tions.
Chapter 4 contains:
2. At twin crane operation the crane movements
Safety Precautions Checklist for Single and Twin
automatically stop and Synchronizing failure in-
Cranes.
dicator lamp lights if the hooks or jibs get out
of syncronizing position.
Chapter 5 contains, if applicable:
3. The crane has several fail-safe functions for
Inspection of Stressed Components and Structures. over-ruling or stopping the operators
Lubrication chart; Crane. maneuvring in the event that normal hydraulic
Lubrication chart; Twin Platform. or electrical functions fail, a sudden uncon-
Lubrication chart; Cable Winch and Stabilizing Equip- trolled movement occurs or during overspeed
ment. operation (see below).
Lubrication chart; Power Swivel. 4. There are limit switches for reducing speed of
Filters. or stopping all dangerous motions.
b. Hydraulic functions:
Before maintenance and service work is started, cer- 1. Hydraulic valve functions are set for exact pres-
tain measures and procedures must be followed. sure. Any change in the settings adversely af-
fects crane operation and must exclusively be
Chapter 6 contains: set by professional service personnel (see in-
Measures before Starting Service/Maintenance Work. structions Hydraulic function and High pressure
Handling and Checking Steel Wire Ropes. pumps).
Checking brake settings. (Valid for winches equipped 2. Hydraulic oil pressure sensor automatically in-
with low speed motors.) dicate an overload. For safe hoisting or lower-
Electrical Equipment, General Maintenance. ing, the system automatically switch from a
highspeed movement to a lowspeed movement
or may stop the hoisting movement.
3. In case of a ruptured high-pressure oil pipe/hose 4. Heat sensors located in the main electric mo-
or other feed pressure drops, the oil feed pres- tors and feed pump motor stops all crane ope-
sure will collapse. A feed pressure switch stops rations and activates all brakes.
the crane and the mechanical brakes are auto- 5. The overcurrent protections on all electric mo-
matically applied. tors prevent the electric motors from overload-
4. Each winch has a hydraulic motor brake valve ing.
flanged to the motor. Mounted directly to the The main electric motor and feed pump elec-
motor it also provides hydraulic braking in case tric motor overcurrent protections stop all crane
of a pipe rupture. (Valid for winches equipped operations and activates all brakes.
with low speed motors.) 6. A separate electrical feed for the cranehouse
5. If there is brake band failure, e.g. caused by lights operators cab and on jib, maintains func-
worn-out lining, hydraulic braking capacities by tion of lights even during feed disruption to the
the pump and motor brake systems are still a- crane operating functions. As there is not a
vailable. (Valid for winches equipped with low separate emergency illuminating system for the
speed motors.) crane (this is dependent on the ships systems)
6. If there is a multiple-disc failure caused by worn the owner of the crane must provide a battery
out brake discs, sticking cylinder, brake pilot type flash-light for the operators cab.
valve or valve spool, hydraulic braking by
pumps and motor is still avaiable. (Valid for d. Mechanical functions:
winches equipped with high-speed motors). 1. Automatic sensors recognize dangerous wire
7. In case of overheating oil, a temperature sen- slacks and stop hoisting and luffing movements
sor stops the main electric motor, locking crane that threaten safe control and the equipment
operation. itself.
8. Efficient oil filters with exclusive bypass to the 2. Each working circuit has at least two independ-
hydraulic oil reservoir protects the system from ent brake systems.
harmful oil conditions. A warning light on the Dynamic braking, deceleration, is achived by
operator's panel indicates if the filter has to be the regenerative function of motor and pump.
changed. Dirty filter might cause mal function (hydraulic braking).
to the system. True static braking (parking brakes) is pro-
9. If the hydraulic oil tank oil level drops below vided by multiple disc-brakes or band brakes.
the minimum permissible level. There are band brakes for low speed winches
A warning light on the operators panel is acti- and an extra mechanical pawl-brake for luffing.
vated. The mechanical brakes are automatically acti-
An indicator stops the main electric motor and vated in the event of dangerous oil pressure.
crane functions are closed while all brake sys- High speed winches are provided with multi-
tems are automatically activated. ple disc brakes. One for each gear unit.
Each slewing gear unit is equipped with one
c. Electrical functions: multiple disc brake.
1. The crane control system protects the crane
from overload by using pressure sensors. See 2. Safety Installations
also section 3. Crane Control System CC2000..
a. Warning lights, measuring instruments and meters:
2. During a complete power failure all solenoid
1. The operators panel is provided with warning
valves are de-energized, causing brakes to be
lights which indicate clogged filters or low oil
activated.
level in the oil tank.
3. The electronic cabinets have power failure in-
2. During crane start-up a warning light on the
dicators. This function closes the electronic sig-
operators panel indicates that starting proce-
nals down which automatically activates all
dures are still running and that working condi-
mechanical brakes.
tions are not acceptable before the lamp goes b. Safety belt, rescue line, safety chains:
out. Maneuvres are not to be ordered before 1. For maintenance, service or entry to the open-
the warning light goes out. air outside the crane house, personnel must
3. A pushbutton siren is located in the crane op- wear a safety belt. The connector hook should
erators cabinet, allowing the operator to alert be anchored to rails and fixed position while
persons in the working area (e.g. against pro- staying or working on crane top.
hibited riding on the load or against load move- 2. The rescue line and equipment for emergency
ments). evacuation of the crane operator must always
4. Measuring instruments and meters (e.g. for be easily accessible on the interior wall-side of
checking the crane functions, adjusting valve the crane cabin. The equipment status and
positions, and setting functional positions) are completeness must be inspected regularly by
supplied as per agreement with the crane the responsible officer onboard.
buyer/owner. Tools and equipment which are 3. The safety chains on the open-air crane top
eliminated from the original order to and work platforms inside the crane, must be
MacGREGOR are delivered at the discretion used for attendants safety during stay and
of the owner. work.
CAUTION SIGN
WARNING SIGN
WARNING SIGN
Attached to the crane wall surfaces close to winches.
PM40 7106-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed during drum rotation.
Adequate caution must be regarded.
WARNING SIGN
Attached to brackets and walls of work platforms inside crane
PM40 7107-E00 RISK OF GETTING CAUGHT BETWEEN BRAKE CYLINDER AND WALL - WATCH OUT!
During service or replacement work, the serviceman may be exposed to the power of released
brake cylinders.
WARNING SIGN
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7109-E00 RISK OF FALLING DOWN - USE SAFETY BELT!
During any visit to the crane top (e.g. for service jobs), the authorizing officer and the person
entering to the area must fully understand the risks involved.
WARNING SIGN
The safety belt must be worn during any visit to the crane top.
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7110-E00 UNIT UNDER CONSTANT SPRING TENSION. USE PRESCRIBED TOOL FOR SERVICE
The label warns of the release of tension power of brake cylinders.
The exposed force of cylinders might expose personnel to specific risk.
CAUTION SIGN The risk is exposed only during service or replacement work.
CAUTION SIGN
Attached to fan houses on the open-air crane top and to wall surfaces near the top roof of the
crane.
PM40 7112-E00 RIDING ON CARGO FORBIDDEN
For the attention of the crane operator, to observe that the crane is a Cargo Handling device.
The crane operator is obliged to stop operation and to alert any person riding to keep off. The
DANGER SIGN
operators alarm bell, in the crane operators cabin, may be used, preferably.
Attached to surfaces inside the cranehouse, close to pumps, valves, pipes and manifold blocks.
Also in the foundation close to oil tank and pipes.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7117-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-
vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment and boxes where 110 V or 440 V is exposed after covers are
removed.
PM40 7118-E00 RISK OF FALLING DOWN - APPLY SAFETY CHAIN!
During any visit to the work platforms, the authorizing officer and the person entering the area
must fully understand the risks involved.
WARNING SIGN The safety chains (at work platforms) must be used to prevent personnel from falling.
Attached to the steel bracket side at the open-air crane top platform, and at the crane work
platforms inside the crane house.
PM40 7119-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN BEFORE MAIN SWITCH (Q1) IS SWITCHED OFF!
AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-
DANGER SIGN vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
DANGER SIGN
This sign is attached to the steel bracket side of the open-air crane top entry.
PM40 7124-E00 RISK OF BODILY INJURY. EMERGENCY OPERATION, AUTHORIZED PERSONNEL ONLY
OPERATE WITH UTMOST CARE, SEE INSTRUCTION
Emergency operation of luffing and slewing, in the event of complete power failure or main
DANGER SIGN pump unit failure, is extremely difficult and dangerous.
This operation must be undertaken with great care and only by skilled personnel. Instructions
must be observed at all times.
Attached to the wall side of the crane operators cabin.
PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!
The working area of the crane, over deck as well as over the deck-sides, is dangerous for
personnel, equipment or property. Items lifted or articles dropped may cause death, injury or
DANGER SIGN severe damage.
The crane operator must stop operation and alert personnel.
The operators alarm bell must also be used for attention.
Attached on both sides of the crane jib.
PM40 7127-E00 220V INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
This sign is attached to the steel bracket at the open-air crane top entry.
PM40 7140-E00 HIGH VOLTAGE, SEPARATE FEED, EVEN WHEN MAIN SWITCH (Q1) IS SWITCHED OFF.
AUTHORIZED PERSONNEL ONLY.
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-
DANGER SIGN vers or hoses are removed.
Boxes with this sign are powered even if main switch has shut off other electrical power. Access
is restricted to qualified and authorized personnel only.
Attached to electric cabinet CT1.
PM40 7142-E00 HIGH VOLTAGE INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
electrical supply.
DANGER SIGN
Access is restricted to qualified and authorized personnel only.
Preface
General
Contents list; Safety; Conversion tables; Hydraulic
and electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operators checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equip-
ment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.
General Instructions
Cleanliness in Hydraulic Systems
General
The fundamental and foremost rule in all work with Use a brush for cleaning, wipe off with a non-
hydraulic systems and components is absolute linting rag, repeat the cleaning if necessary. Fin-
cleanliness. ish by spraying the area of operations - hose con-
nections etc. - with the solvent.
Many components, e.g. valves and pumps, have 4. Mount protective covers immediately after remov-
very narrow tolerances, therefore microscopic im- ing a component, a pipe or a hose. Components,
purities, invisible to the human eye, may have dis- shall also be fitted with covers and plugs in order
astrous effect on the function of a hydraulic sys- to prevent ingress of dirt.
tem. These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
The hydraulic system installation contains a cleaner the workshop.
with a cartridge designed to stop impurities pro- 5. Observe minute cleanliness when handling all
duced within the hydraulic system during operation. types of quick-release connectors. Spray both
Every care must be taken to prevent external im- connectors with solvent before making up a con-
purities from entering the system when servicing or nection. Clean all covers before reinstallation.
repairing it.
Storing and filling up of hydraulic oil
This also applies for components that have been
1. Store barrels, hoses and pump as clean as pos-
removed and or to be reinstalled. Sooner or later, a
sible and best of all in a warm room. The oil vis-
component that has been replaced will be inspected
cosity will then be considerably lower, which
in a test equipment somewhere. It is important that
make the filling through filter easier.
the component stays in the same condition as it was
2. Barrels, hoses and pump must be carefully han-
when it was removed, as it may otherwise be
dled and cleaned when necessary.
impossible to decide the real cause of a malfunction.
3. Store barrels horizontally, so plugs (or cocks) are
It may also be possible that a component sent in
below the liquid level and impurities (e.g., damped
for inspection is not defective at all, and will be
air) does not penetrate the barrels.
returned.
4. Observe minute cleanliness when filling up oil -
carelessness is one of the greatest sources when
Rules when working on the hydraulic system impurities penetrates the hydraulic system.
The following fast rules shall be observed during 5. Fill up hydraulic oil. See separate instruction.
working on the hydraulic system: 6. Never use the last drop in the barrel, as it often
consists of water and other impurities depend-
1. Carry out a rough general clean-up. ent on how many times the barrel has been
2. Protect the area where work shall be done. Use opened.
a sheet of plastic material or similar.
3. Clean well with white spirit or a similar solvent.
Remember that it is not enough to clean only the
parts immediately concerned, but also their sur-
roundings from where accumulated dirt may be
transferred in to the repair area. Do not forget to
clean the tools to be used.
Conversion Factors
Length Pressure
1 mm = 0,0393701 in (tum) 1 atm = 14,6959 lbf/in2 (psi)
1 m = 3,28084 ft (fot) 1 atm = 1,01325 bar
1 in = 25,4 mm 1 atm = 1,03323 at
1 ft (fot) = 304,8 mm 1 bar = 0,986923 atm
1 at = 14,2233 lbf/in2 (psi)
Volume 1 at = 0,980665 bar
10 lbf/in2 = 0,689476 bar
1 dm3 = 1 litre = 0,219969 gallon (UK)
10 lbf/in2 = 0,70307 at
1 dm3 = 1 litre = 0,264172 gallon (US)
1 bar = 1,01972 at
1 gallon (UK)= 4,54609 dm3
1 bar = 14,5038 lbf/in2 (psi)
1 gallon (US)= 3,78541 dm3
1 kp/cm2 = 14,2233 lbf/in2
1 bar = 100 kPa = 0,1 MPa
Mass 1 Pa = 1 N/m2
1 kg = 2,20463 lb 1 Pa = 10,2 10-6 kp/cm 2
1 lb = 0,45359 kg 1 Pa = 0,145 10 -6 lbf/in2
1 ton (metric) = 1000 kg 1 Pa = 7,5 10-3 mm Hg
1 ton (UK) = 1 longton (US) 1 kp/cm2 = 98,07 103 Pa
1 ton (UK) = 1016,05 kg
Power
Force 1 kW = 1,35962 hk
1 kp = 2,20462 lbf 1 kW = 1,34102 hp (UK, US)
1 kp = 9,80665 N 1 hk = 0,986320 hp (UK, US)
1 lbf = 4,44822 N 1 hp (UK, US) = 1,01387 hk
1 lbf = 0,453592 kp 1 hk = 0,735499 kW
1N = 0,101972 kp 1 hp (UK, US) = 0,745700 kW
1N = 0,224809 lbf
Temperature
Moment of force 0C = 32F
1 kpm= 9,80665 Nm 0C = 273,15 K
1 kpm= 7,23301 lbf ft 0F = -17,7778C
1 Nm = 0,737562 lbf ft 0F = 255,3722 K
1 lbf ft = 0,135582 daNm 0K = -273,15C
1 lbf ft = 1,35582 Nm 0K = -459,67F
1 lbf ft = 0,13825 kpm
1 daNm = 1,01972 kpm 1
C = (F - 32) F = 1,8 (K - 273,15) + 32
1 daNm = 7,37562 lbf ft 1,8
1
F = C 1,8 + 32 K= (F - 32) + 273,15
1,8
Moment of inertia
C = K - 273,15
1 kg m 2 = 3417,17 lb in2
1 lb in 2 = 0,00029264 kg m2 K = C + 273,15
This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
3. Electric symbols.
Elektrische Schaltzeichen.
1. Hydraulic Symbols
Hydraulische Bildzeichen
Pilot line.
Steuerdruckleitung.
Drain line.
Lecklleitung .
Fixed restriction.
Feste Blende, feste Drosselung.
Variable restriction.
Regelblende, regelbare Drosselung.
Flexible hose.
Schlauch, biegsame Leitung.
Pipe junction.
Leitungsverbindung.
Rotary connection.
Dreh-Verbindung.
Regulation or variability.
Regelbar oder nachstellbar.
Mechanical connection.
Mechanische Verbindung.
Electric motor.
Elektromotor.
M
Filter.
Filter.
Air breather.
Luftreiniger.
Non-return valve.
Rckschlagventil.
Gauge connection.
1
Meanschlu.
Ventilation valve.
Entlftungsventil.
Shuttle valve.
Wechselventil.
Brake cylinder.
Bremszylinder.
Pressure gauge.
Manometer.
Thermometer.
Thermometer.
Oli cooler.
lkhler.
Accumulator.
Druckspeicher.
Shut-off valve.
Absperrventil.
Proportional valve.
Proportionalventil.
Servo valve.
Servoventil.
Cartridge valve.
Patronenventil.
2. Valve Assemblies
Ventil-Baugruppen
Flushing valve.
Splventil.
3. Electric Symbols
Elektrische Schaltzeichen
Make contact.
Arbeitskontakt.
Break contact.
Schaltkontakt.
Main contact.
Hauptkontakt.
Emergency stop.
Notschalter.
Limit switch.
Endschalter.
Pressostat.
Pressostat. P
Level switch.
lstandswchter.
Inductive contact.
Induktiver Geber.
Ammeter.
Strommesser.
A
Voltmeter.
Voltmesser. V
Hour counter.
Stundenzhler. h
Rectifier.
Gleichrichter.
Frequency converter.
Frequenzumformer.
Diode.
Diode.
Light emitting diode.
Leuchtdiode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.
Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Resistor.
Widerstand.
Resistor, non-linear.
Widerstand, spannungsabhngig.
Variable resistor.
Widerstand, regelbar.
Heater.
Heizkrper.
Motor.
Motor. M
Condenser.
Kondensator.
Heater, cabin.
Heizkrper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.
Controller, hoisting.
Steuerknppel, Lastwinde.
GENERAL
WO 2/07021.02LMW-1
TYPE OF CURRENT 3 ~ 50 Hz
MECHANICAL DATA
ELECTRICAL DATA
TYPE OF CURRENT 3 ~ 50 Hz
HYDRAULIC DATA
3
DISPLACEMENT 125 cm /rev
3
DISPLACEMENT vg: 160-0 cm /rev
3
DISPLACEMENT vg: 107.0 cm /rev
3
DISPLACEMENT 125 cm /rev
COOLING CIRCUIT
PUMP TYPE
SEE HYDRAULIC CIRCUIT DIAGRAM POS 6111 289 4533-801
DISPLACEMENT (VARIABLE) 90 cm3 / rev
3
DISPLACEMENT (AUXILIARY) 19,6 cm / rev
PUMP TYPE
SEE HYDRAULIC CIRCUIT DIAGRAM POS 6112 390 8810-801
3
DISPLACEMENT 38.0 cm / rev
Technical Description
Slack wire
sensing devices
Jib top
Main electric
motor
Jib
General
This description covers the 4-rope hydraulic grab crane Raising and lowering of the jib are done by means of a
type "K-4HD". The crane is designed for a temperature luffing winch, the design of which is similar in pinciple to
range of from +50 to lowest ambient working temperature that used for the hoisting movement.
for worldwide trading, according to classification societies.
There are also cranes designed for arctic and tropical Three hydraulic drive sets are installed for the slewing
conditions in the product range. All sizes utilize the same movement. The crane housing is bolted to a slewing
basic machinery but differ in the disposition of bearing with internal teeth and the pinion of the
components. hydraulic drive meshes with these teeth. The crane
can be turned through any number of revolutions,
MacGREGOR hydraulic deck cranes are designed as unless limit switches are installed to prevent this. (This
self-contained units with all the machinery enclosed in precaution would be required when the crane is
the crane housing and thus completely protected against located close to superstructures or deck equipment
damage, ice and corrosion. limiting the slewing arc.)
Each crane is delivered as a complete unit tested To heat the oil to a suitable operating temperature,
electrically, hydraulically and mechanically, ready for the separately driven feed pump of screw type
installation on a pedestal or other suitable foundation generates the heat by circulating the oil in the system.
or for mounting on a crane carriage on deck. The cranes are also equipped with an oil cooler to
prevent overheating.
Heater
Jib The separately driven feed pump generates heat to a
The jib is of completely closed box-girder section and suitable temperature by circulating the oil in the system.
computer designed for minimum weight and high
rigidity. The extra wide jib top gives good stability for
Cooler
cargo and thus ensures good operational features.
Air-type coolers keep the oil at a moderate
temperature even in very hot ambient conditions thus
Cargo handling gear ensuring long oil life and reliable crane performance. The
The swivel, hook, shackles, rings, and chains all have separate cooling pumps are integrated with the hydraulic
ample safety margins for the maximum load to be system. The cooler can be cleaned by washing with
handled by the crane. water. The cooler air inlet is in the top of the crane and
gives high cleanness of the cooling air. positions of the loading cycle.
All four grab motions, hoisting-lowering, opening- An anti-corrosive system basically based on two-
closing, are operated with one single controller. The component epoxy paint which can be coated with all
controller is provided with a cross-shaped guide finishing coats existing today.
where these four grab motions have their own groove.
This prevents e.g. accidental opening of the grab while
hoising, but still ensures free choice of motion in all
Suppliers of paint: International. The painting is carried neutral position when the hydraulic pressure drops.The
out according to the recommendations of the paint main movements of the crane - hoisting, luffing, and
supplier. slewing - can be operated simultaneously without any
speed reduction as well as independent of each other.
Protection and safety features
Automatic cut-outs operate: Testing and inspection
- at full hoist as sensed on the drum Before delivery all MacGREGOR deck cranes are
- at maximum/minimum plumbing depth rigorously function tested in our works. Final adjustments
- at maximum/minimum outreach and overload test are carried out during final installation.
- if cargo wire is slack
- if luffing wire is slack
- maximum oil temperature
- minimum oil tank level
- safety valve overload protection on all motions
Electrical equipment
Electric cables outside the crane house, e.g. on the jib,
are protected by electric conduits. All cables and other
electrical equipment have been specially designed for
marine purposes.
Hydraulic Function
PF
Character legend
Hoisting winch circuits
MHOC Hydraulic motors (2), hoisting/closing circuit
MHOH Hydraulic motor, hoisting/holding circuit
Introduction
MLU Hydraulic motors, luffing circuit
MSL Hydraulic motor, slewing circuit The hoisting winch system for handling the grab con-
PHO Pump, hoisting circuit sists of two separate winches, the closing winch for
PLU Pump, luffing circuit opening and closing the grab and the holding winch
PSL Pump, slewing circuit for holding the grab.
PF Pump, feed circuit
The hoisting winch circuit have the below mentioned
main components:
Feed and control pressure circuits
Pumps
Hydraulic motors
Feed circuit
Brake units
The function of the feed circuit is mainly to provide
feed pressure in the closed circuits, to compensate See the hydraulic circuit diagram, section 9.4.
for leakage in these and to flush them to prevent
overheating. The high-speed motor for holding winch is of fixed
displacement type and for closing winch of variable
Feed oil is supplied to the systems low-pressure side displacement type and are connected to the winches
by non-return valves. The feed circuit works at a by a flange. The transfer of torque to the winch drum
pressure of 1.9 - 2.5 MPa (19 - 25 bar), which is set is by means of a planetary gear.
using valve 4148 and can be measured at tapping 1.
The winches can for grab handling perform in four
Control pressure circuit different operating modes; hoist grab, lower grab,
The function of the control pressure circuit is to close grab and open grab.
supply oil to the brakes and pump servo and thereby
control the speed and working direction of the Hydraulically the winch circuits can be connected
winches and slewing action. The system pressure to three different main positions, hoist/lower open
of 3.0 - 3.5 MPa (30 - 35 bar) may be measured at grab, hoist/lower closed grab and open/close grab.
tapping 2. The control oil is supplied to the pump These main positions are controlled hydraulically
servo by the servo valves and to the brakes by the by direction control valves 1181-2, 1221 and 1226.
brake valves.
Whenever the grab is fully or partially open, the 2. Closing the grab
movements of the hoisting winch are synchronized If the lever is moved further to the left, the
by the speed control to the pumps being controlled grab starts closing. The pumps servo that
electronically. In this position, the main circuits for controls the pump displacement is actuated
the hoisting winches are hydraulically separated. by the levers and the electronic control circuit.
The pumps thereby provide an oil flow that
When operating with a closed grab, the main cir- increases the closing speed in proportion to
cuits are hydraulically connected and the winches the lever deflection.
follow one another by pressure equalization be-
tween the main circuits. When opening and closing 3. Autotension
the grab, the flows of the four hoisting pumps are During the closing phase, autotension may be
connected to the closing winch to minimize the engaged by a pushbutton on top of the left
opening/closing time. control lever in the cabin. Auto-tension affects
valve 1182-2 and opens the connection
Control of the grabs opening position and guidance between direction-control valve 1181-1 and
of the hoisting winches operating positions and se- pressure-regulating valve 1182-1. This implies
quences is done by means of an electronic control that the holding winch motors pressure in the
system. The function position of the direction-con- A circuit diminishes, the winch turns slowly in
trol valves and control system is shown in the "Grab the lowering direction and the grab is lowered
crane control system", Section 3. to a corresponding degree. The idea of the
auto-tension is that the grabs own weight
shall contribute to increasing the grabs
Function excavating ability and degree of filling. The
force in the holding lines is determined by the
a. With the control lever in the neutral position pressure in the motor by the pressure-
(Figure 2) and the main pumps idling without the regulating valve 1182-3.
hoisting winch circuit performing any work, the
circuits are flushed continually and leakage is com- Whenever the grab is completely closed, the
pensated by the supply of oil from the feed circuit. main circuits are connected hydraulically by
The hydraulic main circuits are separate in this valve 1181-2 moving to position b. This is
position if the grab is open and hydraulically con- controlled by the limit position for the closed
nected if the grab is closed. grab.
Valve 1181-2 does not change position when When the grab is closed the hydraulic main
the brakes open in the hoisting/lowering circuits are connected and the flow from the
direction, but retain the same position as four hoisting pumps is distributed between
when the control lever is in the neutral the closing and holding winch motors,
position. depending on the distribution of power
between the winches. The flow to the closing
During brake release with fully or partly open winch motors is greater than that to the
grab, valve 1221 is actuated in "a" postion, holding winch motors when hoisting and low-
means high-speed position, half ering with a closed grab. The pumps servos
displacement on the closing motors. are actuated by the lever and control system
in a corresponding manner as when closing
Lowering
and opening the grab, where the hoisting and
lowering speed increases in proportion to the
lever deflection.
If the lever is moved more to the front/rear, Overload and safety system
the winches start hoisting/lowering the open
grab. When the grab is open, the winches are a. Overload functions
synchronized by angle transmitters on the
The overload system is controlled by electric
winches and the electronic control system.
pressure switches and the hydraulic pumps
To synchronize the winches, the faster one
pressure cut-off valves as follows:
is subject to a speed reduction. The speed
- Pressure switch 1311 for the cargo position
control to the four hoisting pumps increases
- Pressure switch 1312 and 1313 for hoisting/
at increased lever deflection as well, so that
lowering in grab position and grab closed
the speed increases in proportion to the lever
- Pressure switch 1314 for hoisting/lowering in grab
deflection.
position and grab open
- Pressure cut-off valves 1111-10, 1113-10, 1112-10,
and 1114-10 when opening and closing the grab.
Lowering
Cooling circuit, hoisting, and luffing
winches
The slewing gears are fitted with an oil circulation The pump (2111) has been adjusted so that it
system for the slewing gear oil. The system provides a small flow from port B with the control
comprises three pumps (one for each slewing gear) lever in the starting position. This prevents the boom
driven by a common electric motor. The gear oil is slowly luffing out.
circulating through filters, one for each slewing gear.
Safety system
The pump motor is always running when crane is
The luffing circuit contains the following safety
started.
functions:
Pump Introduction
Hydraulic motor The cranes slewing system have the below
Brake unit mentioned principal components:
See the hydraulic circuit diagram, section 9.4. Pumps, variable displacement
Hydraulic motors
Function Valve unit
In the starting position, valve 2221 is actuated, in Brake cylinders
position b when luffing in and out.
See the hydraulic circuit diagram, section 9.4.
Luffing is controlled by a variable pump 2111 and
motor 2141. The pump provides a flow out from port Brake release
A when luffing out and out from port B when luffing If the control lever is moved to the left, for example,
in. The amount of the flow is controlled by the to move the crane to the left (anticlockwise) valve
position of the control lever. 3221 is activated. The brakes open and unloading
unit 3127 is blocked.
The motor is always subjected to load in the same
direction, so that high system pressure only occurs Slewing right/left
on the B side of pump 2111.
If the lever is moved more to the side, the crane will
start to slew in the direction selected. The pumps
Starting position servo valve will be actuated and will angle out in
proportion to the lever deflection and supply oil to
Neutral position the hydraulic motor. To slew to the right (clockwise),
the lever must be moved to the right, which provides
Starting position the same function except for the direction of flow of
the oil through the pump.
Safety system
The slewing circuit contains two safety functions:
Introduction
The purpose of the present description is to furnish a Note! - The hydraulic oil must be warm before the
general idea of the design and function of the electric crane may be started.
system. The crane is supplied with electric power via
the slipring unit and the main switch in the crane
house. Cables lead from the main switch to: a trans- Starting and stopping the crane
former supplying power for all control circuits; a switch
Start sequence
for the oil cooler fan motor; a Y/D switch for the main
- Press button S13 "1" (Start)
electric motor; pole switches for the feed pump
- Warning lamp H1 "DO NOT OPERATE" illuminates
electric motors; and a thermostat switch for the ven-
- Feed pump motors M2/M22 start by contactors K11
tilation fan in crane house.
and K10. The motors run at their full speed of 2900
rpm (50 Hz) or 3500 rpm (60 Hz).
All components are marked by symbols in the dia-
gram, making it easier to follow the various stages of
The feed circuit pressure build up its operating pres-
the starting sequence, e.g.
sure. Pressostats BP1 - hoisting circuit, BP2 - luffing
circuit, close and start a delayed closing 8s time relay
- Contactors: K1 (N); K3 (D); K2 (Y)
K71.
- Contactors: K11; K10
- Time relays: K9; K71; K70
- N contactor K1 and Y contactor K2 switch on the
main motor M1, which starts in Y connection.
- At the same time as the Y contactor was switched
Preparing for starting the crane
on, an 8s delayed-opening time relay, K9, was star-
Summer ted.
Outside temperature above +5oC - After 8s, the Y contactor drops, and D contactor
K3 is switched on by time relay K9.
- Set WINTER/SUMMER switch S50 to SUMMER.
The D contactor and self-holding N contactor switch
- Close main switch Q1 - ON
main motor M1 to delta configuration.
- Pushbutton "1" (Start) energize also the cool fan
Winter motors Q4/Q24.
Outside temperature below +5oC Motors Q4/Q24 are activated by thermostat BLT1
if the temperature of the hydraulic oil exceeds
- Set WINTER/SUMMER switch S50 to WINTER.
+10oC.
- Close main switch Q1 - ON.
- Warning light H1 goes out. The crane is operatio-
- Feed pump motor M2 starts via contactor K11 and
nal.
run at its full speed, i.e. 2790 rpm (50 Hz) or 3350
rpm (60 Hz).
Overheating protection
Emergency stops
A thermostat BT2 in the hydraulic system of the crane
The crane is equipped with three emergency stops
opens the control circuits of the main electric motor
mounted in the cabin, in the CT1 cabinet and on the
and the oil cooler fan motor when the oil temperature
wall in the lower part of the crane house respectively.
exceeds +85oC. Pilot light H5, HIGH OIL TEMPERA-
A reset button is situated on the right control panel in
TURE, illuminates.
the cabin (H9).
Siren
A pushbutton "SIREN" in the cabin allows the opera-
tor to warn people on deck.
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC2000 for complete electric circuit diagram, relating specifically
MacGREGOR Cranes hydraulic 4-rope grab cranes. to your crane, will be found in the instruction manual,
section Spare Parts, Group 9.5. Also for detailed
Minor variations in the use of control system input information about the hydraulic system a complete
and output signals due to differences in hydraulic and hydraulic circuit diagram can be found in section
electric system may occur. The objective of this Spare Parts, Group 9.4.
description is only to provide a general orientation
concerning the principles of the control system.
Cabinet CT2
Grab,
Unloading valve
holding winch HOISTING
Hydraulic Hydr.
MPC
motor
Control lever hold pump (s)
hoisting winch, "Ho"
holding/closing Limit switch
Displacement Brake valve box encoder
valve
Grab,
closing winch
MPC
close Hydr.
Hydraulic motor
"CL" pump (s) Limit switch
1181A box encoder
MPC Unloading Brake valve
1181B
"Sc" valve Unloading valve
1182
Luffing winch
Control lever MPC LUFFING
"Lu" Hydraulic Hydr.
luffing/slewing pump (s) motor
MEM
Limit switch
box
Brake valve
Unloading valve
Memory
card MPC Slewing gear
Hydraulic Hydr.
"SL" pump (s) motor SLEWING
Limit switch
box
Unloading valve
Fig. 1. Crane control system with interfaces to control levers, hydraulic system and grab.
Control levers (joysticks) The voltage to current amplifier feeds the hydraulic
The right control lever controls the hoisting winches pump solenoids.
(closing winch and holding winch), see. Fig. 1. The
left control lever controls the luffing and slewing Hydraulic pumps
movements. The control levers linear potentiometers
The hydraulic pumps are variable displacement
are fed with 0V, +6V and +12V. The output level is
pumps (e.g., the flow is steplessly variable from zero
approx. +6V with the control lever in neutral. The out-
to max. rated flow). The pump oil flow is controlled by
put signal is controlled by the lever and is decreased
a 24V pulse width modulated (PWM) current signal.
to approx. +1.5V and increased to approx. +10.5V,
The direction of the oil flow is dependent on which
depending on the lever movement.
one of the two solenoid valves is activated.
Limit switch box, luffing and the grab therefore goes down into the cargo during
The limit switch box controls speed reduction and stop the closing motion. If the grab digs too deep, the crane
function for all max. and min. outreach, and stop operator can release the auto-tension. This interrupts
parking, if fitted. the lowering of the holding winch and the jaws will
move upwards during the closing operation.
When the grab has closed completely the closing
Limit switches, slackwire
action stops.
The limit switch for hoisting, holding and closing, slack-
wire stops the lowering movement, and the limit switch
luffing slackwire stops the luffing out movement when Hoisting the closed grab
a wire is slack. By moving the lever in the "hoist" direction, the crane
operator can start hoisting the closed grab.
Immediately prior to final closing of the grab, the
Limit switches, slewing
control system has prepared the winches for lifting
If fitted, the limit switches for slewing controls speed
the closed grab by interconnecting the hydraulic
reduction and stop function for each direction at maxi-
systems for the two winches. During hoisting, the dist-
mum slewing range.
ribution of load between the closing winch and the
holding winch is predetermined. Normally the closing
Crane control system - principle for Grab winch carries 51% of the load and the holding winch
operation 49%. The load distribution is independent of the
magnitude of the load.
The 4-rope grab crane comprises two grab winches,
the closing winch and the holding winch. The winches
can be controlled independently or together. There is Lowering the closed grab
a separate drive unit, hydraulic pump and motor, for Lowering is controlled by the right lever. The winches
each winch. The winches are controlled by a single are hydraulically interconnected.
lever. The same hoisting/lowering lever controls brake
opening. The crane is prepared for use with both Opening the loaded grab
clamshell and scissors grabs.
When moving the control lever to the right, "opening",
the grab opening starts. Grab opening is stopped by
Control of empty open grab the control system when the grab is fully opened.
The grab is supported by the holding winch ropes and During the opening action, the grab is supported by
the closing winch follows the holding winch. The right the holding winch. The opening can be stopped at
lever controls hoisting or lowering. The speed is any position. Stepless control allows slow release of
infinitely variable. When the grab is lowered by this cargo.
lever onto the cargo, lowering is stopped either by
the driver or by the slack-wire switch. Hoisting or lowering of open grab
The winches are synchronized so that the closing
Synchronization of the winches when the grab is open
winch follows the holding winch maintaining the grab
is achieved with encoders on both winches connected
opening angle. The holding winch carries the weight
to the control system. Arbitrary opening can be
of the grab and the closing winch follows, without
selected.
carrying any significant load.
12
11
4
9
10
6
8
1. Cabinet 7 Plinths
2. 19" rack with electronic cards 8. Anti-condensation heating
3. MPC cards (Micro Processor Cards) 9. Sign: Signal overview
4. Parameter list 625 XXXXX 10. Sign: Error messages
5. Parameter memory card 11. Open grab potentiometer
(mounted on the backplane card) 12. Encoder calibration
6. Cables from MPC cards to plinths 13. Encoder Interface Card (AIC)
19" subrack with electronic cards Each MPC card is a complete stand-alone
microprocessor system with processor, several types
All electronic cards are mounted in a standard 19"
of memories and communication channels, analogue
aluminium subrack. A backplane card is used for
and digital inputs as well as analogue and digital out-
connecting power 8V and 24V to the MPC cards. It
put current drivers.
also provides communication lines between the MPC
cards and between one MPC card and the parameter
Each card can fully handle all input and output sign-
memory card.
als needed for one hydraulic circuit, i.e. one crane
movement. A separate safety system on each card parameter values are not dependent on power supply
gives processor-independent protection against or battery. There is, however, a battery on the card
hazardous operation at low feed pressure and used for a calendar, giving all MPC cards date and
overload pressure as well as ensuring the stopping time information. The card is located inside the rack
of the crane movement due to activated limit switches. and is mounted on the backplane card that also holds
all the MPC card connectors.
Software The lifetime of the battery is 10 years.
All five MPC cards are programmed with the same
crane control software. Each card senses which rack-
Cables from MPC cards
position and therefore which crane movement it is
Each MPC card has a maximum of 42 cables
controlling.
connecting all the inputs and outputs between the card
and its part of the plinth row. Cables are numbered 1
All MPC cards identifiy themselves by showing a two-
to 42 and put together in a cable loom.
character abbreviation of the function/movement-
name on the front panel display: Sc - supervisor, Ho -
hoisting, Lu - luffing, SL - slewing, CL - closing. Plinths
All external connections are made to a row of plinths
The leftmost MPC card, the MPC Sc, is used for in the lower part of the enclosure.
supervisory functions such as communication with
other MPC cards and distribution of control system Each MPC card has its own series of plinths as
parameters from the parameter memory card. In a follows:
grab system it also controls hydraulic valves for 101 - 142 for the MPC Sc
interconnection of the hydraulic circuits (1181A, 201 - 242 for the MPC Ho
1181B), the Auto-tension valve (1182) and the "Grab 301 - 342 for the MPC Lu
Open" and "Grab Closed" lamps. 401 - 442 for the MPC SL
501 - 542 for the MPC "CL"
New versions of the crane control software can be
loaded/programmed into the MPC cards by using a Note that not every number has a corresponding
standard notebook PC. plinth and that a particular crane does not necessarily
use every plinth for external connections.
Parameter list Plinth numbers from 1 to 99 are used for power and
cross-connections for external limit switches, key
The parameter list specifies all information details
switches, overload switches etc.
about the crane needed for the control system. It sta-
tes the software version and software configuration
parameters such as number of pumps, type of pumps, Anti-condensation heating
maximum speed, extra equipment etc. To avoid condensation on the electronic cards, the
temperature inside the enclosure is kept a few degrees
The parameter list identification number 625XXXXX, above the temperature outside. Heating elements are
is the same as the crane manufacturing number seen therefore mounted behind the row of plinths. They are
on the sign in the operator's cabin (Mfg. No.). All para- powered with 24V AC when the control system is
meters are stored in the parameter memory card. switched off or when the crane is not operational.
Signal overview CC2000 The system checks itself and external input and out-
put signals. Internal problems such as loss of
communication are continuously checked. Loose
Coloured LEDs
connections to pumps and valves are detected when
Signals to and from each MPC card are indicated by
the output is activated. Signal levels that do not
green, yellow and red LEDs (Light-Emitting Diodes)
correspond to normal levels, i. e. the potentiometer
on the front panel of each MPC card .
input from the operator's handle, are also detected.
Error messages
General
Function
With the main switch in position "1" (on-position)
the ventilation fan starts via a thermostat, positioned
in the CT1 cabinet, see Fig. 2. The thermostat bulb
is situated outside the cabinet.
Fan
Fan
CREW CHECKLIST
BEFORE OPERATION
Note! When the crane is rigged ready for operation, all keys for all lockable switches must be stored in a safe
place by the officer responsible on board.
Read sections Operation and Maintenance in the instruction manual and make sure that maintenance is
performed refer to Maintenance Chart.
Make sure that nobody enters the crane without permission from the responsible officer on board.
Make sure that there is nobody in the crane house who might be caught in the machinery or strangled by the
wire ropes.
When the outside selector shall Switch the main Unclamp jibs and loose gear
temperature is be set to SUM- switch to position Unclamp the jib, loose gear or
more than +5C ... MER. "1". grab from its parking position.
Winter
b. Winch overheated
Trim
1. The crane control system CC2000 stops.
Make sure that the ship does not trim more than 2 2. Make sure that the oil cooler fan is running (under
degrees. the cabin).
3. Wait for temperature to fall. When the pilot lamps
go off the crane is ready for operation.
c. Oil level
Max. 2
1. Examine the oil level in the oil tank.
2. Fill oil if necessary (see Lubricating Chart).
3. Examine the oil coolers (crane top).
OPERATING INSTRUCTION
Air Conditioning
Operating Instruction
This unit is a versitile air conditioning unit equipped with cooling, heating, and dehumidifing features, all integrated
in one single compact unit. Their ease of use provides a quick and easy way to maintain constant room temperature.
FAN (ONLY) - Turn the main switch to position "AIR COND". Fan starts.
- Control switch (B) in position "1".
COOLING - Turn the main switch to position "AIR COND". Fan starts.
- Control switch (B) in position "2". When cooling compressor
- Thermostat (A) set at desired temperature (i.e. +20 C). running the green
COMP-lamp (C) will lit.
HEATING - Turn the main switch to position "AIR COND". Fan starts.
- Control switch (B) in position "3". When heating element is
- Thermostat (A) set at desired temperature (i.e. +20 C). operating the yellow
HEAT-lamp (D) will lit.
DEHUMIDI- - Turn the main switch to position "AIR COND". Fan starts.
FICATION - Control switch (B) in position "4". When dehumidifier is in
progress both green (C)
and yellow (D) lamp will lit.
ERRORS There are two built-in thermostats for safety running. If the air
conditioning unit is not working properly, please, before contacting
service, allow the compressor or the heating element to "cool
down" for at least 30 minutes by turning the main switch into
position "0".
CONTROL PANEL
A TEMP.SET
* Main switch:
See Controls and Indicators, Chapter 4.
1. FAN
B 2. COOL
3. HEAT
4. DEHUM.
Controls:
C A Operating thermostat.
COMP.
B Control switch, cooling or heat.
D HEAT C Pilot lamp, compressor on.
D Pilot lamp, heating on.
4 5 6
CT4
7 8 9
10 11
13 14 15
16 17 18
19 20 21
22 23 24
25 26 27 41
Summer
Start - acceleration Retardation -stop When outside temperature is above +5C set
switch in SUMMER position. Set main switch
Speed
max.
in position "ON" (1).
Winter
When outside temperature is below +5C set
Time switch in WINTER position. Set main switch in
2 sec. 2 sec. position "ON" (1) some 24 hours before opera-
tion.
Acceleration Retardation
S51 EMERGENCY STOP
Fig. 3. Luffing. Pushbutton. Stops the complete crane in case
of emergency. The pushbutton has to be reset,
otherwise the crane cannot be re-started.
Hour meter
Q1 - Main switch
CT4 - Operating box, eccenter platform CT11 - Electric Cabinet, eccenter platform
(HPL9) ALARM
Buzzer.
See separate instruction PM46 2517-E00.
Fig. 6. Electric cabinet CT11, eccenter platform.
AD1 Display
Shows information to the crane operator, for
example load in hook, jib outreach and hoisting
speed. See instruction PM40 6713-E00.
OPERATING INSTRUCTION
START - STOP
MacGREGOR cranes are designed for operation in harbour or sheltered water environments where there is no
significant movement of the ship due to wave action.
WARNING!
Only ship's crew is allowed to operate key switches. Keys must be stored in a safe place by responsible officer.
Make sure that there is nobody in the crane house who might be caught in the machinery or strangled by the
wire ropes.
START
STOP
STOP
- LET GO the control levers; they
If the crane gets out of control...
will return automatically to their
neutral positions. Press pushbutton, position 0
- Press Emergency Stop button! (STOP).
Note! Calibration of absolute encoders for open and closed grab to be done before taking crane into operation or
after replacement of wire. See instruction 6.303.35 E in cabinet CT2 (MB).
WARNING! Do not move Key switch CARGO/GRAB HANDLING from the GRAB position, if the grab is raised.
The grab will close in an uncontrolled manner which can cause death or personal injuries.
Grab handling mode (right lever) Cargo handling mode (right lever)
- Switch CARGO/GRAB HANDLING to position GRAB - Switch CARGO/GRAB HANDLING to position CAR-
XX Ton. GO XX Ton.
- Open and close, and lower or hoist grab with right - Both holding and closing winches are hydraulically
lever. connected to each other.
CARGO/GRAB CARGO/GRAB
HANDLING HANDLING
Lowering Lowering
CARGO SEP. RUN GRAB CARGO SEP. RUN GRAB
xx Ton xx Ton xx Ton xx Ton
x-xxm x-xxm Grab Grab x-xxm x-xxm
closing opening
TEST TEST
ADJ. ADJ.
Hoisting Hoisting
- Key switch CARGO/GRAB HANDLING in position - Key switch CARGO/GRAB HANDLING in position
SEP. RUN. TEST/ADJ.
Holding and closing hydraulic circuits are separated. In this position the grab limit, controlled from cabinet
Synchronizing of winches is disconnected. CT2/MB, is inactivated.
HOISTING/LOWERING lever movement actuates the This feature may be utilized when checking and
holding winch pump. setting the limit positions for open and closed grab.
Close the stop cock 1247 and 1249. The holding and closing winch is operated in speed
CLOSING/OPENING lever movement actuates the reduce.
closing winch pump. Adjustable "Open Grab" limit potentiometer located
Close the stop cock 1248 and 1250. in cabinet CT2 (MB), see instruction 6.303.35 E.
CARGO/GRAB CARGO/GRAB
HANDLING HANDLING
CARGO SEP. RUN GRAB CARGO SEP. RUN GRAB
xx Ton xx Ton xx Ton xx Ton
x-xxm x-xxm x-xxm x-xxm
TEST TEST
ADJ. ADJ.
CRANE OPERATION
Luffing in Hoisting
With the slewing/luffing control le- When control lever is in neutral To give a smooth acceleration and
ver in neutral, the brakes are en- position brakes are engaged and retardation to the winch movement
gaged. holds the load. the control system is fitted with a
ramp former with a special ramp
Moving the lever a short distance Hoisting/lowering time.
from neutral releases the brakes. Moving the control lever a short
Moving the lever left or right starts distance from neutral releases the Force closed
the crane to slew in the direction brake for both holding and closing To use force closed function press
chosen. winches. pushbutton on top of right control
lever.
Moving the lever forwards or back- Holding the control lever in this posi-
wards starts operation of the luffing tion will keep the load at constant
winch. height. The position of the lever is
depending on the load on the hook.
Auto-tension
To use auto-tension press pushbut- Moving the control lever further-
ton on top of the left control lever to more in hoisting or lowering di-
facilitate filling of grab. rection means continued speed
increase from zero to maximum
speed up or down.
CRANE OPERATION
Grab Grab
opening closing
Hoisting
Left lever
FORCE CLOSED
OPERATING INSTRUCTION
Crane/Eccenter Platform
START - STOP
MacGREGOR cranes are designed for operation in harbour or sheltered water environments where there is no
significant movement of the ship due to wave action.
WARNING!
Only ship's crew is allowed to operate key switches. Keys must be stored in a safe place by responsible officer.
Notify responsible officer onboard before taking crane and eccenter platform into operation.
Make sure that there is nobody in the crane house or in eccenter platform who might be caught in the
machinery or strangled by the wire ropes.
START
STOP
If the crane gets out of control... - LET GO the control levers; they
will return automatically to their
neutral positions. Press pushbutton, position 0
- Press Emergency Stop button! (STOP).
Note! Grab limit switch adjustment to be done before taking into operation or after replacement of wire. See instruction
6.303.35 E.
Grab handling mode (right lever) Cargo handling mode (right lever)
Grab Grab
closing opening
Grab Grab
0 1 Hoisting 0 1 Hoisting
2 2
Right lever Right lever
2 2
CRANE OPERATION
Verify that ship does not list more Dragging loads is not permitted!
than 5 degrees and does not trim
more than 2 degrees. Do not drag loads - lift them.
ECCENTER PLATFORM
Note!
The eccenter platform and the crane must NOT be turned at the same time. The eccenter platform can be
turned with load in the hook/grab.
How to position/park the eccenter platform, see instruction PM46 2517-E00. After positioning/parking the eccenter
platform the electric motor should be stopped by pressing the stop button.
The Start/Stop button for the eccenter platform is to be found on the separate box, CT4, on right hand wall in
the cabin. Approx. 5 minutes after start the machinery automatically stops by a time relay.
START STOP
The diagram
The centre part of the screen shows a diagram
visualizing the current load in hook and jib radius
once more in addition to the text values displayed
in the grey boxes. This visualization also indicates
all limits and possible movements for the crane.
The current values are indicated by a white ball
with a black circumference. The areas displayed in
the diagram are defined by parameters. The green
area indicates normal operation, the yellow
indicates speed reduced and the red border is the
Fig. 1. Main screen.
stop limit.
Communication
In the lower left corner of the display there will
appear "COM1" or "No connection". COM1
indicates communication with the CC2000 at the
moment. No connection means that for some
reason there is no communication between the
program and the CC2000 system.
Error indication
An error in CC2000 is indicated with the text Error
CC2000, in red in top middle, below the crane
mode.
Caution! (or both) of the lock pins is (are) not in the exact
All keys for all lockable switches must be stored in a locking position, the eccentric platform can be
safe place by the officer responsible on board. inched to the required position. See Fig. 2 and 3.
- The red lamp "PARKING LOCK ENGAGED" should
now illuminate. See Fig. 2 and 4.
Slewing of eccentric platform to parking When operating the parking pins proximity switch is
position activated. See Fig. 7.
(Located on
the right side
wall.)
Operator's
seat
Alarm
Fig. 3. Indications when parking lock is not engaged. Fig. 4. Indication when parking lock is engaged.
Lock pin
Parking lock
Introduction
Prior to sea voyage, the jib/jib extension should be put When the jib enters the parking area the function "Force
on its parking support, see Fig. 2. The hook is to be Limitation" is automatically activated. This function
stowed to deck, fibrestrops with low ultimate load or limits the pull in the hoisting wire rope to reduce stress
manual stretching screw must be used. If the hook is in the steel structure of the crane and parking
not secured to deck a jib safety lock is recommended to arrangement. See also instruction "Limit Switches in
lock the crane jib in the parking support. See Fig. 3. ..." in section 6.3.
PARKING OF JIB
0 0
1 1
Rope connection
Stretching screw
Notice! Hand-tighten
turnbuckle
only to the extent that
Deck the tightening gear is
not slack.
Important!
The wire ropes must not be tightened too hard. The Chain
crane structure, wire ropes, sheaves, and winches
are subject to heavy stress during sea voyage.
Jib
support
Rope
Example:
Before operating crane No. 1 carefully check that crane
No. 2's jib has been removed from its parking support,
see Fig. 5.
Crane No. 2 Crane No. 1
Example:
Jibs parked in their jib supports on the foundation Before operating the crane carefully check that the
towards each other. Hook secured to deck, see crane jib has been removed from its parking
Fig. 6. support.
Example: Important!
The grab should be lowered to the deck when the Power cable and stabilizing cable should be parked
crane is parked, this to avoid load on the wires. on jib top during sea voyage. Parking on hook block
is for temporary use only.
Turnbuckle
Support Support
SIDE VIEW TOP VIEW
Example: Example:
Fix block
with wire
ropes
Deck Deck
Fig. 8. Power swivel with lifting block secured to deck. Fig. 9. Power swivel secured to deck.
Maintenance Chart
Lubricate crane according to LUBRICATING Wire ropes, wire rope clamps, pears and
CHART. shackles
Winches
- Check oil level. See instruction, section 6.1. Oil
Every 100 operating hours
quantity to be found on the name plate and in
instruction "Technical Data", section 2.
Slewing bearing screws
- Inspect visually the slewing bearing from the deck
Filter service indicators
and inside pedestal. If any screw shows a
- Check filter service indicators.
tendency to slacken, tighten all screws with a
- If necessary change filter cartridges, see
torque wrench or a hydraulic tensioner see
instructions "Filters", section 5.
drawings "Slewing bearing, yard mounting" and
"Slewing bearing, mounting", section 9.3.
Oil filter, eccenter platform
- Check pressure (manometer) before taking crane Pumps
into operation. The pressure must not exceed 1.7
- Check for leakage.
bar (0.17 MPa).
Pump servo
Every 500 operating hours
- Check plussing
- If necessary adjust.
Ventilation with filter (optional)
- Check filter bag. Change if necessary. See
Air conditioner (optional)
separate instruction.
- Check that the unit is securely fastned and not
damaged. See instruction, section 5.
Slewing bearing
- Grease sampling, see instruction 625/1579 E.
Hydraulic hoses
- Replace all hydraulic hoses. See instruction in
section 6.1.
Air Conditioning
Maintenance / Trouble-shooting / Service
Maintenance
This air condition unit is designed for an ambient tem- - Is the fuse in the electric box, from where the supply
perature between -20C and +40C. to the unit is taken, in order?
Inside the cabin the unit will maintain a temperature - Is the operating thermostat working properly? Test
between +18C and +30C. this by turning the thermostat knob on the control
The unit is designed to be installed from inside the roof panel from -10C to +20C. The compressor light
of the cabin and does not require any regular shall go off by this operation.
maintenance. Instead we recommend you to carry out
an operation check now and then to make sure the unit
is working properly. Service
Trouble-shooting Warning!
Problems usually appear from one of three areas: Incorrect installation or not fixing the unit properly,
- Power supply. may lead to personal injuries if the unit is falling
- Objects in front of the unit which stops air circula-tion. down.
- Evaporator or condenser has choked flanges. If a leakage of refrigerant would appear there is a
risk for frost-bites or burns if in direct contact with
Check up the following: the refrigerant in hotgas or liquid phase.
- Is the power cord plugged in to the unit? The refrigerant in this unit must not be released to
- Is the main switch on the control panel in the position the enviroment.
"AIR COND"?
Project No: 2/0702102LMW1 2011-08-18
Valid for: 62507582
1 (4)
5 MAINTENANCE
MAINTENANCE 5.006.2 E rev.: - 1999-12-01
Filter bags
Cap with filter
Cover, eccenter platform
Cover
Removal
- Open the cover
- Remove filter bags. El. motor
Installation
- Install sealing if necessary. A proper and airtight Fig. 2. Ventilation with filter.
installation is important for good filter performance.
- Install filter bags with the pockets in upright posi-
tion.
- Check that the pockets are free to be inflated by
the air flow.
- Be sure that the filter is properly installed and air-
tightnened.
Introduction
Stressed parts of the crane structure subjected to This inspection should be performed at intervals ac-
high loads require inspection for signs of cracks and cording to the Maintenance Chart.
other damage at regular intervals.
Note!
Cracks detected at an early stage do not generally Rust on a painted surface does not necessarily
impair the handling safety of the crane unless they mean that there is a crack in the underlying mate-
are not repaired. rial.
Example:
5 MAINTENANCE
Item Part of crane (see page 2 for location) a b c d e f
1 Wire sheaves, Jib top: 1 nipple/sheave (8-10 nipples); Thimble, 1 nipple *
2 Swivel, 1 nipple
3 Wire sheaves, Crane house, 1 nipple/sheave (10-11 nipples) *
4 Door hinges
5 Electric motors, upper and lower bearings, 2 nipples
6 Air breather cap
7 Luffing winch, rear bearing, 1 nipple
8 Oil tank
9 Hydraulic oil drain
10 Slewing bearing - See drwg. section 9.3 for nipples **
11 Slewing bearing teeth
12 Jib bearing, 2 nipples
13 Hoisting winch (holding and closing), rear bearings, 2 nipples
14 Hoisting winch (holding and closing), oil change
15 Slewing gear case, oil change
16 Luffing winch, oil change
17 Wire ropes
18 Shackles and wire rope pears
19 Oil filters, service indicators, 4135-4136, 4350-4352 ...; 4354-4356 ...
20 Beams, 4 nipples
Check what number of nipples that apply to your crane. It Key to symbols
* is of utmost importance that all nipples are greased. Grease for ball and roller bearings
Grease for plain bearings
** IfRelubrication should be performed under slewing motion.
that is not possible relubricate bearing through all grease Grease for wire ropes
fittings, then turn bearing approx. 200 mm and relubricate
again. Repeat this procedure until overlap of greasing is Grease for open spur gears
achieved and the whole bearing circumference is filled Grease for jib bearings
with new grease at the gaps and seals. (Five rotations/ Oil level, check
greasings should be sufficient.)
Oil filters, check
Air breather cap, check
Hydraulic oil, oil change
Gear case oil, oil change
The first oil change to be done after 200
KEY TO SYMBOLS working hours (running-in period)
a DAILY (ITEM 19 EVERY 8 WORKING HOURS)
b EVERY 50 WORKING HOURS
Gear case oil, oil change
The first oil change to be done after 200
c EVERY 200 WORKING HOURS OR EVERY TWO MONTHS working hours (running-in period)
d EVERY 500 WORKING HOURS OR EVERY SIX MONTHS
e EVERY 1000 WORKING HOURS OR EVERY YEAR Slip-rings to be treated according to
f EVERY 2000 WORKING HOURS OR EVERY TWO YEARS separate instruction, see section 6.3.
5 MAINTENANCE
Red lamp on right control panel in operators cabin Jib top and lifting block
1 1 1
1
1
CAUTION!
Renew all filter cartridges
when this lamp is lit. 1
2
19
3. Wire sheaves
18 18
17 17
18 18
19 Oil filling
Filter 4136-1
5. Electric motors
4. Door hinges
Eccentric platform
KEY TO SYMBOLS PART OF CRANE a b c d e f
f EVERY 2000 WORKING HOURS OR EVERY TWO 6 OIL TANK (APPROX. 250 LITRES)
YEARS
3
7
5 2
Filters
Introduction
For cleaning hydraulic oil, the hydraulic system is The other indicator is visual (see Fig. 1) and should
equipped with two filters. The two filters are marked be read when the oil temperature is approximately
4135 and 4136. 45C. Upon reaching a certain degree of clogging, a
red indication can be seen on the top of the filter
Filter indicators indicator. Replace both filter cartridges in the system
when the red indication shows.
The filter indicators operate only when the crane
starts.
Replacement of filter cartridges
Filter 4135 has two filter indicators. One indicator is You must replace both cartridges (see Fig. 3) in the
electric and operates a warning lamp placed on the crane at the same time. Flush all other parts of the
control panel in the cabin (see Fig. 4a and 4b). filters with white spirit when you replace the cartridges.
Use new seals. Reassemble the filters.
Filter Filter
4135 4136
Filter Indicator
The filter is equipped with a filter indicator and
functions only when the crane is started.
Filter element
O-ring
Indicator
Filter
Indicator
For cleaning hydraulic oil in the eccentric platform, Pressure should be checked by use of a manometer
the hydraulic system is equipped with a filter. The (6182) every time before operating the platform. If
filter is installed on the oil tank, see Fig. 1, and is the pressure exceeds 1.7 bar (0.17 MPa) the filter
marked 6131. element and O-rings must be replaced.
O-ring
Filter element
O-ring
Filter indicator
The filter is equipped with a filter indicator and
functions only when the cooling system is running.
Example:
Fig. 1. Filter units in winch gear cooling system. Fig. 3. Filter cartridge.
Filter indicator
The filter is equipped with a visual filter indicator, see
Fig. 2, and should be read when the oil temperature
is approx. 45C. Upon reaching a certain degree of
clogging, a red indication can be seen on the top of
the filter indicator.
Example:
The hydraulic oil tank is placed on the crane house Wipe the tank dry with clean rags. DO NOT USE
floor. The feed pump is located inside the oil tank. COTTON WASTE, or other linting material. Apply new
The main pump unit drive gearing is continually sealing compound and reinstall the tank cover.
lubricated by oil from the hydraulic system, surplus
oil being returned to the tank by a drain line. If the drained oil is in good condition and can be used
anew, it should be filtered before refilling.
Checking oil level
Pump and hoses used for filling must be perfectly
The oil tank has a dipstick to indicate the oil level.
clean.
Check that oil level is between min. and max on the
dipstick.
Fill oil to just under the MAX mark on the dipstick.
Use oil according to the Lubricating chart.
Oil level float switch
4
If the oil level drops below a certain minimum level an
oil level float switch installed in the oil tank, operates
alarm signals on the control panel in the operator's
cab.
3
Filling oil
Oil is filled at an aero-quip type quick-release 1
coupling, placed on the filter unit, see Fig. 2. When
filling oil the hydraulic system must be at rest and the
electric power switched off. 6
7
Oil filling
Flush the tank with white spirit.
Fig. 2. Oil filter
Project No: 2/0702102LMW1 2011-08-18
Valid for: 62507582
1 (2)
5 MAINTENANCE
MAINTENANCE 5.302.17 E rev.: - 1999-06-28
The hydraulic oil tank is placed in the eccentric Wipe the tank dry with clean rags. DO NOT USE
platform. The pump unit drive gearing is continually COTTON WASTE, or other linting material. Apply new
lubricated by oil from the hydraulic system, surplus sealing compound and reinstall the tank cover.
oil being returned to the tank by a drain line.
If the drained oil is in good condition and can be used
Checking oil level anew, it should be filtered before refilling.
The oil tank has a dipstick to indicate the oil level.
Check that oil level is between min. and max on the Pump and hoses used for filling must be perfectly
dipstick. clean.
Filling oil 6
8
Fill oil to just under the MAX mark on the dipstick.
Use oil according to the Lubricating chart.
7
NOTE! Oil must not be filled directly into the tank.
1
2
Cleaning the oil tank
Before cleaning the oil tank, immobilise the platform
in a suitable manner, push the stop button and switch
off the power. Drain off the oil into clean empty barrels 9
or drums.
Fig. 1. Oil tank
Remove the tank cover. Scrape off sediment, if any,
from the tank bottom and sides using a rubber scraper. 1. Quick coupling, oil 5. Oil filter
drain 6. Quick coupling, oil filling
Flush the tank with white spirit. 2. Vedge valves 7. Thermometer
3. Air filter with dipstick 8. Hydraulic hose
4. Oil level and temper- 9. Ball valves
ature guard
A. OILS B. GREASES
Pump Hose
Number of particles equal to or larger than 4 m(c), ISO code More than Up to and including
not to exceed code 19. 26 320 000 640 000
Number of particles equal to or larger than 6 m(c), 25 160 000 320 000
not to exceed code 17. 24 80 000 160 000
Number of particles equal to or larger than 14 m(c), 23 40 000 80 000
not to exceed code 14. 22 20 000 40 000
21 10 000 20 000
Analysis using microscope sizing 20 5 000 10 000
We recommend cleanliness code -/17/14 or better, 19 2 500 5 000
according to ISO 4406:1999. 18 1 300 2 500
17 640 1 300
Number of particles equal to or larger than 5 m, 16 320 640
not to exceed code 17. 15 160 320
Number of particles equal to or larger than 15 m, 14 80 160
not to exceed code 14.
13 40 80
12 20 40
Procedure if oil sample is showing too high 11 10 20
contamination 10 5 10
9 2,5 5
If the oil analysis shows too high contamination, the 8 1,3 2,5
oil and the filters should be changed. The crane
7 0,64 1,3
should be driven for approximately 1 hr and a new
6 0,32 0,64
oil sample should be taken and sent for analysis.
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
Part description
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
Delivery details such as: consignee as well as phone and fax numbers
Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
Cargotec Sweden AB
MacGregor Cranes
SE-891 85 RNSKLDSVIK, Sweden
Phone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.macgregor-group.com
Confirmation of
phone call/conv.
6. See enclosure
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
2011-08-18 Project No: 2/0702102LMW1
Valid for: 62507582
SERVICE 6.000.1 E rev.:6 cSERVICE
2007-01-08
Paragraph A.1.2 stipulates that the following MacGREGOR (SWE) AB, rnskldsvik
exceptions to the requirements of paragraph A.1.1 Quality Department
may nevertheless be allowed:
Section B
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
1) the part
2) from where it has been taken and
3) why it is returned.
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ships name:
IMO no.:
Returned parts
drawing or article
no, serial no.:
Part description:
*) Please note: To be filled in with short but specific details. Faulty is not enough, a much better
description is leaking, not adjustable, cracked, earthing fault, short circuit if the reason is obvious,
or, a circumstantial evidence pointing to the returned part as the reason for malfunction, like luffing
movement too slow in one direction.
Introduction
As a first check always try to operate the crane and Analysis of information collected
at the same time check the status of the trouble- By methodical trouble-shooting, it is often possible
shooting panel in the CT2 (MB) cabinet (see to find, at an early stage, the defect producing the
instruction in section 6.3). faulty operation, thereby avoiding unnecessary
waste of time.
Also measure the feed pressure at gauge outlets 1
and 16. Check the control pressure at gauge outlet
2. Pressure setting levels can be found in the pressure All important pressure adjusting devices are sealed.
setting list on the hydraulic circuit diagram. Breaking a seal voids the guarantee unless done with
the explicit consent of MacGREGOR Cranes.
When consulting MacGREGOR Cranes for service
or advice, always give the following information at
once:
Holding winch
1. Is the fault electrical, electronic, hydraulic, or
mechanical in nature?
2. In which function does the fault appear:
- Hoisting circuit
- Luffing circuit
- Slewing circuit
3. Is the trouble limited to:
- Raising or lowering of the load - open or close
grab (which winch has problem, holding or closing
winch?)
- Raising or lowering of the jib
- Slewing right or left
4. Special observations: Closing winch
- Is the holding, closing, luffing or slewing capacity
restricted? Fig. 4.
- Do disturbances occur only at certain speeds?
- In the event of abnormal noise:
- To which of the main functions does the noise
pertain?
- Is the frequency of the noise high or low?
- Try to describe the noise (hissing, blowing,
humming, rasping etc.)
5. What is the status of the electrical trouble-
shooting panel in CT2 (MB) cabinet?
6. Have pressures been measured?
- Feed circuit pressure
- Control circuit pressure
- Hoisting circuit high pressure
- Luffing circuit high pressure
- Slewing circuit high pressure
WARNING !
When it is necessary to search for/or correct faults
in the crane's electrical, hydraulic or mechanical
systems with the crane powered up, only author-
ized personnel may carry out such work.
A. Overheating in hydraulic sys- 1. Oil cooler fan does not work or Check direction of rotation,
tem. rotates in wrong direction. connections and contactor.
Effect repair as required.
Note!
When the hydraulic system is overheated thermostat BT2 (+85oC) opens.
Pilot light H5 "HIGH OIL TEMP" in cabin illuminates when the temperature
in the winch gears exceeds 95C and exceeds 85C in the hydraulic sys-
tem.
Pumps, general
A. Pump not supplying any fluid. Servo error. Contact MacGREGOR Cranes
B. Excessive wear of the pump. Hydraulic fluid contains abra- Check filters. Change cartridge,
sive particles. if necessary. Analyze sample
of the fluid.
C. Fracture of parts in the pump. Pressure shocks. Check valve functions and valve
settings.
Slewing Gearset
Oil filling Air filter - Fill gear oil as required (see lubricating instructions
Expansion tank for appropriate type; the approximate quantity
Plug a needed is given on the nameplate).
Expansion pipe
- Fill brake disc chamber with hydraulic oil; e.g. 0,1
litre ATF-oil, type A.
Disc brake
Brake surface sealed with Loctite type 573.
- Before assembling the drive motor, grease shaft
Oil level sight
glass and gear teeth with a suitable grease for protection
against corrosion; we suggest OPTIMOLY PASTE
White T.
- Check function of slewing gearset with the drive
motor running, paying particular attention to the
Screws holding function of the brake and the correct control of the
gearset to crane
house floor motor.
Oil outlet
Maintenance
Lubrication
Fig. 1. Slewing gearset. The slewing gearset is splash lubricated. The output
shaft roller bearing is for-life lubricated with ball
Assembly of slewing gearset bearing grease.
- Install slewing gearset in crane without using force. Oil level check
- Use hand pump to release disc brake hydraulically. Inspect oil level when the gear is at rest with the brake
Input drive sleeve must turn easily. engaged.
- Check slewing gear backlash (pinion-to-rim gear).
See description under Checking and adjusting
Oil changes
slewing rim backlash.
- The gear backlash may be adjusted by rotating the Whenever practicable, let the oil drain off while still
gearset one or more screw hole divisions. hot; remove also the filler plug(s).
- Tighten the screws to torque recommended, secure
with Loctite 242 (or a similar compound). Applying For oil change open both pipes. Remove air filter with
a suitable sealing compound, such as Loctite 640, oil expansion tank at marked pos. a, see Fig 1.
on the mating surfaces of the flanged connection,
is recommended. At low ambient temperatures, flush out the gearcase
- Remove threaded plug from top of expansion pipe with a quantity of fresh oil to remove abraded matter
(for transport sealing only). and contamination products.
- After installation of gear unit fit supplied air filter
with oil expansion tank, at marked position a
(optional to fit with a tube turn). See Fig. 1.
Sampling oil
Withdraw a sample of gearcase oil for inspection from If coarser abraded matter (above 25 ) or flake off
the filling drained off at intervals as described in the material from the gear teeth is found, the gearset must
Maintenance Chart. To obtain a representative be dismantled, irrespective of the actual amount of
sample, drain the gearcase during operation and with foreign matter present, beginning at the input end of
the oil at operating temperature. the gearset.
Oil discoloration
Hydraulic-Release Multiple-Disc Brake
A darkish or black colour of the used oil suggests that
temperatures in excess of 100o C did occur in opera- Technical description
tion, causing accelerated aging of the oil and impaired The brake comprises the following major components:
lubricating properties. In this case the oil should be - Brake piston
changed at shorter intervals. - Brake cylinder
- Disc carrier
If the oil sample displays a cloudy aspect, it may be - Internal discs
that water has managed to seep into the oil. The oil - External discs
must then be changed a t o n c e, and the gearcase - Sealings
flushed out very thoroughly several times with fresh - Thrust spring
oil.
The brake housing is mounted on top of the gearcase,
The gearcase should preferably be dismantled for with long assembly screws through the motor adap-
inspection beginning at the input side, and the ter housing and both parts of the brake housing.
components examined for signs of corrosion.
The sleeve disc carrier, with the internal discs, is fixed
Foreign solid matter on the driven shaft with a shaft key or by splines.
Motor side
Thrust spring Brake piston Brake cylinder
Pressure oil
connection Sealing
Sealing
Total
thickness Leakage oil
of discs
Disc carrier
Internal discs
External discs
Gear side
- Inspect brake discs and replace if excessively - Slew the crane 90 degrees and check.
worn. - Proceed to check the backlash at four 90-degree
- If discs are coloured dark yellow to blue, the discs position in the rim.
have been overheated. Replace discs and springs. - Put the dial gauge on the tooth of the pinion. By
- Inspect sealings for wear. If sealings are defect manual turning at the input, the pinion can be moved
replace brake cylinder and piston with sealings to in both directions up to contact with the teeth. Now,
new ones. the tooth flank clearance can be exactly measured
on the dial gauge.
b. Brake heats - Check the backlash at one spot
Check the hydraulic pressure to make sure that it is - Slew the crane 90. Check again
sufficient in order to disengage the brake completely. - Proceed to check the backlash at four 90-degree
positions in the rim
- Compare the four backlash values.
Checking and setting slewing rim Backlash values: See drawing "Slewing
backlash assembly".
An oversize backlash between the pinion and the The backlash shall be set at the position of the slewing
slewing rim will cause irregularities in the slewing rim with the lowest backlash value.
movement of the crane. Read this instruction carefully
prior to checking or resetting! Setting backlash
The backlash may be set by turning the entire gearset
Checking backlash one or more screw hole divisions.
The backlash should be checked by a dial gauge or
a feeler. When slewing the crane, the backlash may Proceed as follows:
vary from one position to another due to some slight - Slew the crane into the position with the lowest
excentricity of the slewing rim. It is therefore backlash value.
recommended to check the backlash at four positions - Remove all screws holding the gearset to crane
of the slewing rim. house floor.
- Release the disc brake hydraulically by means of a
Proceed as follows: manual pump.
- Check the backlash at one spot.
Note!
The turning of the entire gearset may be restricted by Upper part
the hoses connected or by space limitations. To over-
come this problem, release the upper part of the Screws
gearset by just removing the holding screws, see Fig.
3 Slewing gearset.
Screws holding
Make sure that the upper part can be turned freely. gearset to crane
house floor
Turn the entire gearset (except the upper part), until
the desired setting is achieved. Watch the hoses!
Hydraulic Motors
Hoisting, Luffing, and Slewing Circuits
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Displacement: 40 cm3/rev.
Pre-filling volume: 1.0 litre (approx.)
Oil filling
Drain connection
Oil filling
Hydraulic motor 189 3383-801
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Winch
General
The luffing winch is driven by one high speed hydraulic Gear box oil filling / Oil dipstick
Note! Before removing the oil dipstick,
motor with fixed displacement via a planetary gear remove vebtilation filter..
box. The planetary gear box has splash lubrication After checking the oil level reinstall ventilation
filter.
and is filled with gear oil.
Ventilation filter /
A brake is integrated in the winch gear set. When the Oil filling inlet for
winch is running the brake is released by hydraulic wet running
pressure. Connection
for oil cooler
feeding
The winch is equipped with two temperature switches.
One low temperature switch, 55 - 50C, which is
normally open and one high temperature switch, 100-
Connection for oil
95C, which is normally closed. cooler draining
Assembly
- Mount the winch together with winch support. The
clamping screws of the winch support must easily
be connectable.
- Tighten the screws according to torque
recommended. Secure with Loctite 242 or a sim-
ilar compound. Oil drain
- Connect brake line and release disc brake
hydraulically. The drive sleeve in the drive unit must
turn easy. Fig. 1. Winch with oil filler inlet and dipstick
- Remove plug off the drive sleeve of the drive unit.
For protection against corrrosion the drive sleeve
is provided with gear oil from the gear. The plug
- The rope winch is normally filled with oil. If the
prevents a filling with oil of the motor flange before
winch is supplied without oil, this is indicated on a
mountage of the motor.
corresponding label.
- Before test-running, fill the motor flange completely
- Oil volume: See name plate on winch or instruction
with oil.
"Technical Data", section 2.
- Center motor in the the motor flange. Fix motor
- Oil type: See instruction "Lubricants for Deck
with screws. Motor shaft must be grease-free.
Machinery", section 5.
- Remove plug off the vent pipe and mount the air
- Check rope winch with running motor as to function.
filter.
Check above all the control and function of the
- Check oil level with oil dipsstick.
holding brake and the drive motor.
Note! Before removing the oil dipstick remove
- After test-running check oil level once more with
pressure relief valve. After checking oil level
oil dipstick. During the test-running, the oil level in
reinstall ventilation filter.
the gear and motor flange is adjusting itself and
Refill oil if necessary.
fills the space around the motor shaft slowly with
gear oil. Therefore the oil level may be reduced.
- If necessary, refill oil. - Special oil sampling bottles should be used and
- The journal bearing is filled with grease. Before can be obtained from oil companies.
taking into operation grease again until grease - The oil sample should be taken from the oil drain
emerges at the sealing profile. on the winch, see Fig. 1.
- Insert rope and fix it. Secure screws accordingly. - Drain 1-2 litres of oil into a bucket. This oil should
be disposed of.
Maintenance - Fill the oil sample bottle.
- Send the oil sample to an oil company for analy-
The planetary gear of the winch has splash lubrication
sis.
and is filled with gear oil.
The oil company will be able to recommend if the
oil can be further used.
- Fill gear oil as required. See lubricating instructions
Feedback on the oil analysis can also be obtained
for appropriate type. The approximate quantity
from MacGREGOR Cranes.
needed is given on the name plate or in instruction
Technical Data, section 2.
- The bearing of the second journal bearing is filled Oil discoloration
with grease. A darkish or black colour of the used oil suggests
Before taking into operation grease again till grease that temperatures in excess of 100C did occur in
emerges at the sealing profile. operation, causing accelerated aging of the oil and
- Daily inspection of oil level, see Fig. 1. impaired lubricating properties. In this case the oil
should be changed at shorter intervals.
Note! Oil level can only be inspected with non-running
gear. If the oil sample displays a cloudy aspect, it may be
that water has managed to seep into the oil. The oil
- "Lubricants for Deck Machinery", see instruction must then be changed at once, and the gearcase
under section 5 flushed out very thoroughly several times with fresh
- Oil change, see instruction "Maintenance Chart" oil.
under section 5.
The gearcase should preferably be dismantled for
inspection beginning at the input side, and the com-
Oil changes ponents examined for signs of corrosion.
Whenever practicable, let the oil drain off while still
hot. Remove the inlet plug (air filter). At low ambient
Foreign solid matter
temperature, flush out the gearcase with a quantity
- As a first simple test, drop some of the used oil
of fresh pre-heated oil to remove particles and
onto the filter fleece specified. Coarse foreign
sediment.
matter, if present, will then show up on inspection,
preferably through a magnifying glass. - A better
test may be made by diluting an oil sample with n-
Gear case and oil inspection heptane, passing it through a diaphragm filter,
washing and drying it, and weighing it to determine
Sampling oil the mass difference.
If the contamination keeps within these limits, contin- Hydraulic-Release Multiple-Disc Brake
ued operation of the gearset is permitted after the oil
has been changed. Description and Maintenance
Motor side
Connect
pressure oil
Ventilation filter
(for leakage oil) Outer disc Arrangement of Inner discs Disc carrier
the brake discs
Gear side
Maintenance
The brake is self-adjusting.
Trouble-shooting
Braking torque insufficient
Brake heats
Check the hydraulic pressure to make sure that it is
sufficient in order to disengage the brake completely.
Holding/Closing Winch
General
The holding and closing winches are mounted in a The planetary gear boxes have splash lubrication
common winch support. and are filled with gear oil.
The closing winch (lower) is driven by two high A brake is integrated for each hydraulic motor.
speed hydraulic motors via a planetary gear box. When the winch is running, the brake is automatically
released by hydraulic pressure.
The holding winch (upper) is driven by two high
speed hydraulic motors via a planetary gear box. Both holding and closing winches are equipped with
a pressure roller, see Fig. 1, to keep the wire in
correct position on the drum.
1
Holding winch
2
3
7
6
4 1
5
8
3
Closing winch
4
6
1. Grease nipple.
2. Pressure roller.
Assembly Maintenance
- Mount the winch together with winch support. The The planetary gear of the winch has splash lubrication
clamping screws of the winch support must easily and is filled with gear oil.
be connectable.
- Tighten the screws according to torque - Fill gear oil as required. See lubricating instructions
recommended. Secure with Loctite 242 or a sim- for appropriate type. The approximate quantity
ilar compound. needed is given on the name plate or in instruction
- Connect brake line and release disc brake Technical Data, section 2.
hydraulically. The drive sleeve in the drive unit - The bearing of the second journal bearing is filled
must turn easy. with grease.
- Remove plug off the drive sleeve of the drive unit. Before taking into operation grease again till grease
For protection against corrrosion the drive sleeve emerges at the sealing profile.
is provided with gear oil from the gear. The plug - Daily inspection of oil level, see Fig. 1 and 2.
prevents a filling with oil of the motor flange before
mounting of the motor. Note! Oil level can only be inspected with non-
- Before test-running, fill the motor flange completely running gear.
with oil.
- Center motor in the the motor flange. Fix motor - "Lubricants for Deck Machinery", see instruction
with screws. Motor shaft must be grease-free. in section 5.
- Remove plug off the vent pipe and mount the air - Oil change, see instruction "Maintenance Chart"
filter. in section 5.
- Check oil level with oil dipsstick. Refill oil if
necessary.
Note! Before removing the oil dipstick remove Oil changes
pressure relief valve. After checking oil level
reinstall pressure relief valve. Whenever practicable, let the oil drain off while still
- The rope winch is normally filled with oil. If the hot. Remove the inlet plug (air filter). At low ambient
winch is supplied without oil, this is indicated on a temperature, flush out the gearcase with a quantity
corresponding label. of fresh pre-heated oil to remove particles and
- Oil volume: See name plate on winch or instruction sediment.
"Technical Data", section 2.
- Oil type: See instruction "Lubricants for Deck
Machinery", section 5. Gear case and oil inspection
- Check rope winch with running motor as to function.
Check above all the control and function of the
Sampling oil
holding brake and the drive motor.
Take a sample of gearcase oil for analyse at intervals
- After test-running check oil level once more with
as described in the "Maintenance Chart".
oil dipstick. During the test-running, the oil level in
the gear and motor flange is adjusting itself and
Procedure for oil sampling:
fills the space around the motor shaft slowly with
- The oil temperature in the gearcase should be
gear oil. Therefore the oil level may be reduced.
above +40 0C.
- If necessary, refill oil.
- Special oil sampling bottles should be used and
- The journal bearing is filled with grease. Before
can be obtained from oil companies.
taking into operation grease again until grease
- The oil sample should be taken from the oil drain
emerges at the sealing profile.
on the winch, see Fig. 1.
- Insert rope and fix it. Secure screws accordingly.
- Drain 1-2 litres of oil into a bucket. This oil should Foreign solid matter
be disposed of. - As a first simple test, drop some of the used oil
- Fill the oil sample bottle. onto the filter fleece specified. Coarse foreign
- Send the oil sample to an oil company for analysis. matter, if present, will then show up on inspection,
The oil company will be able to recommend if the oil preferably through a magnifying glass. - A better
can be further used. test may be made by diluting an oil sample with n-
Feedback on the oil analysis can also be obtained heptane, passing it through a diaphragm filter,
from MacGREGOR service organisation. washing and drying it, and weighing it to determine
the mass difference.
Oil discoloration
A darkish or black colour of the used oil suggests Overall assessment
that temperatures in excess of 100C did occur in The maximum permissible amount of foreign matter
operation, causing accelerated aging of the oil and carried by the oil is some 0.15 per cent of the total
impaired lubricating properties. In this case the oil mass of the oil in the gearcase. These impurities
should be changed at shorter intervals. must be, exclusively, very fine abraded matter (max
25 ). If the contamination keeps within these limits,
If the oil sample displays a cloudy aspect, it may be continued operation of the gearset is permitted after
that water has managed to seep into the oil. The oil the oil has been changed.
must then be changed at once, and the gearcase
flushed out very thoroughly several times with fresh If coarser abraded matter (above 25 ) or flake off
oil. material from the gear teeth is found, the gearset
must be dismantled, irrespective of the actual amount
The gearcase should preferably be dismantled for of foreign matter present, beginning at the input end
inspection beginning at the input side, and the of the gear set.
components examined for signs of corrosion.
Motor side
Connect
pressure oil
Ventilation filter
(for leakage oil) Outer disc Arrangement of Inner discs Disc carrier
the brake discs
Gear side
- Disc carrier
- Inner discs
- Outer discs
- Oil pressure unit
- Pressure springs
- Ventilation filter
Maintenance
The brake is self-adjusting.
Trouble-shooting
Braking torque insufficient
Brake heats
Check the hydraulic pressure to make sure that it is
sufficient in order to disengage the brake completely.
Introduction
Function of thermostats
Normal operation
Thermostat BT2 stops the complete crane when the
oil in the hydraulic system reaches +85. 6 11 12 11 10 5
Pump
Flange
Electric motor
Caution!
Maintain cleanliness throughout removing/dismantling
and reassembling the pump unit(s).
Warning!
Disconnect all electric power to
the crane, before installation.
All pumps are the straight axial piston type with CARGO/GRAB
variable displacement controlled by a servo valve HANDLING
mounted on the pump housing. CARGO GRAB
SEP.
xx Ton xx Ton
RUN
x-xxm x-xxm
The pumps are equipped with two adjustments, one for
plussing and the other for pressure adjustment (max. TEST
working pressure). Plussing of the pumps is done to ADJ.
compensate for internal leakage in pumps and motors
and to prevent load drops (see Fig. 3).
Fig. 3. Pump.
- No load on hook and no list or trim on the ship. Luffing pump (s)
- Actuate valve 3221 manually with a small screwdriver,
see Fig. 4. and Fig. 10. - Install a pressure gauge, 0-400 bar, at connection
- Ensure that the crane does not move in any direction. 5.1, see Fig. 9.
- If the crane does move, an adjustment must be made - Close valve 2661, see Fig. 9.
on the slewing pump(s) using the zero setting - Adjust the pressure cut-off valve on the luffing
screw. (see Fig. 3). If there is more than one pump, pump(s). See paragraph Setting of pressure cut-off
the upper pump should be adjusted. valves, page 3.
- Set key switch for Cargo/Grab handling to desired - Open valve 2661.
position. - Set key switch for Cargo/Grab handling to desired
position.
2011-08-18 Project No: 2/0702102LMW1
Valid for: 62507582
2 (6)
6 SERVICE
SERVICE 6.127.47 E rev.: a 2010-05-06
Slewing pump(s) - Adjust the valve on the lower pump by backing off the
- Install a pressure gauge, 0-400 bar, at connection 6.1 setting screw until a little lower pressure can be seen.
or 6.2, see Fig. 10. - Turn in the screw 1/4 of a revolution on the lower
- Close valve 3661, see Fig. 10. pump.
- Back off adjustment screw.
- Adjust the pressure cut-off valve on the luffing Installation of a complete new pump
pump(s). See paragraph Setting of pressure cut-off
valves, page 3. When a new pump is installed, the pressure cut-off
- Open valve 3661. valve has to be adjusted (see Adjustment of the
- Set key switch for Cargo/Grab handling to desired pressure cut-off valves).
position.
Note! These valves are sealed and the seals must not
Setting of pressure cut-off valves be broken.
Adjustment and replacement of these valves must be
The setting procedure is different depending on if there done by qualified personnel only.
is one or two pumps in the circuit. For identifying the Contact the Service Department at MacGREGOR
number of pumps in the circuit, see hydraulic circuit Cranes for information about valve adjustment.
diagram.
Valve
1221
Valve
1248
Connection
4.1
Valve Connection
1247 3.1
Valve
2661
Valve
2221
Connection
5.1
Valve
3661
Connection
6.2
Valve
3221
Connection
6.1
Fig. 1. Pump.
Hydraulic hoses assembled inside crane house If the rubber in the hose is damaged so that the steel
should be inspected for damage every five (5) years, core can be exposed to corrosion the hose should be
see Maintenance Chart in section 5. replaced.
If the rubber in the hose is damaged so that the steel The hose couplings should also be inspected for
core can be exposed to corrosion the hose should leakage and damage of the corrosion protective Den-
be replaced. syl tape. If the corrosion protection is damaged so
The hose couplings should also be inspected for that the coupling can be exposed to corrosion the
damage and leakage. If the coupling is damaged or corrosion protection should be removed and the
severely corroded the hose should be changed. coupling inspected for damage and severe corrosion.
If the coupling is leaking the coupling should be tighte- If the coupling is damaged or severely corroded the
ned at first. If tightening does not help, the hose and hose should be changed.
the mating couplings should be changed, see Fig. 1. If the coupling is leaking the coupling should be tighte-
If the coupling is of flange type the O-ring and screws ned at first. If tightening does not help, the hose and
should be changed, see Fig. 2. the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
Hydraulic hoses and couplings should be changed, see Fig. 2.
assembled on outside of crane house
Replacement of hydraulic hoses
Hydraulic hoses assembled on outside of crane house
should be inspected for damage every two (2) years, All hydraulic hoses assembled inside crane house
see Maintenance Chart in section 5. should be replaced after ten (10) years due to safety
reasons.
All hydraulic hoses assembled on outside of crane
house should be replaced after five (5) years due to
safety reasons.
Hose coupling
Screw
Fig. 1. Hose coupling with O-ring. Fig. 2. Flange coupling with O-ring.
New design
Valve guard
Protective
Gas valve cap
Protective cap Gas valve Open/close
Valve guard hexagonal nut
Open/close
hexagonal nut
7. New design, see Fig. 1. Open the hexagonal nut 10. Close the nitrogen cylinder valve.
on the gas valve counter-clockwise to stop, by 11. Open the bleed screw of the three-way valve to
using a 19 mm fork wrench. discharge the pressure in the filling hose.
7a. Old design, see Fig. 2. Screw in the filling screw 12. Adjust the reducing valve to zero.
of the three-way valve but not so tightly that the 13. Unscrew the charging equipment from the nitro-
gas valve of the accumulator is damaged. gen cylinder and from the accumulator.
8. Fill nitrogen. 14. Check tigthness of accumulator gas valve, us-
9. New design, see Fig. 1. Check the nitrogen ing soap water.
pressure when the temperature and the pressure Note! - The protective cap shall be fitted with an
of the gas become stable. When the correct O-ring which must fit correctly into its groove.
charging pressure has been obtained, close the 15. Screw on protective cap of the gas valve.
gas valve by turning the hexagonal nut clockwise 16. After charging the accumulator, fit a lable carry-
by use of the 19 mm fork wrench. ing the charging date and signed by the operator.
9a. Old design, see Fig. 2. Check the nitrogen
pressure when the temperature and the pressure Note! For charging, it is not necessary to install a
of the gas have become stable. When the correct reducing valve on the nitrogen cylinder.
charging pressure has been obtained, again
back out the filling screw of the three-way valve.
Old design
Filling screw, to be
used for old design
Pressure gauge
Bleed valve connection
Hose
Max. 10 mm Max. 8 mm
Tightening Torques
Studs/Screws and Bolts
Introduction
Phosphatized bolts greased with Molykote R 1000 Untreated bolts greased with Molykote R 1000
(Also valid for bolts greased with Loctite 243 or oil.) (Also valid for bolts greased with Loctite 243 or oil.)
As a rule, always change screws with specified tight- Stainless bolts and hydraulic pipe couplings
ening torque on cranes in operation if the joint has to greased with Gleitmo paste
be opened for some reasons.
Thread Tightening torque in Nm
If any joint has been opened apply Intertuf after tight- d 10 Nm 1 kpm
ening the joint to avoid rust damage. Austenite (A)
50 70 80
6 3.3 7 9.3
8 7.8 17 22
SAE flange for high pressure hose couplings
10 15 33 44
Tightening torque in Nm 12 27 57 76
Flange Screw 10 Nm 1 kpm 14 43 91 121
6000 psi Class H 10.9 and 12.9 16 65 140 187
18 91 195 260
3/4" M10 54
20 127 273 364
1" M12 94
22 171 367 490
1 1/4" M14 150
24 220 472 629
1 1/2" M16 230
27 318 682 909
2" UNC 3/4 377
30 434 930 1240
33 585 1250 1670
36 755 1620 2160
39 969 2080 2770
Strength class Min. ultimate strength Min. tensile strength Corresponding strength
N/mm2 (kp/mm2) N/mm2 (kp/mm2) class of nuts
Examples of markings:
Hexagonal screw Allen screw
Strength class 4.6: Strength class 12.9:
BH 12 9 M
Hexagonal nut
Strength class 8:
Tightening Torques
Hydraulic Couplings
Example: GE 10 - LM
Table 1. Sealing
d = 10
Fitting
Sealing cone
Insert the sealing cone into the 24-degree coupling
fitting, firmly tighten the coupling by hand. Using a
wrench, tighten the coupling nut another 1/4 to 1/2
turn. The O-ring should preferably be oiled.
Warning!
There is a risk of falling down when opening or
closing the service door. Always use a safety belt!
Note! Before opening the service door you should A. Procedure for opening
always check the condition of the door hinges. Also
make sure that the doors are secured before opening, 1. Put on safety belt.
see Fig. 1. 2. Open window on left-hand side of operator's cabin.
3. Climb out onto ladder (1), see Fig. 2.
Note! Do not forget to secure yourself using safety
belt.
4. Remove three nuts (2) and six washers (3), see
Fig. 2.
5. Climb back into operator's cabin.
6. Close side window.
7. Swing service door outward and secure it using
locking rod (4), see Fig. 3.
2 3
3
Fig. 1. Securing service door to top of crane. Fig. 2. Opening service door.
Note! To be able to properly lubricate the hinges the Fig. 3. Locking rod.
service door must be open.
Hoisting winches
Hoisting winch
holding
Hoisting winch
closing
Luffing winch
Closing ropes
Left-hand lay crane Right-hand lay
Lock washer
Closing ropes
inside grab
Note! The wire rope thimble should be safely secured.
Note!
Set key switch CARGO/GRAB HANDLING in
position SEP. RUN. See Fig. 5.
CARGO/GRAB CARGO/GRAB
HANDLING HANDLING
CARGO SEP. RUN GRAB CARGO SEP. RUN GRAB
XXTon XXTon XXTon XXTon
X-XXm X-XXm
TEST TEST
ADJ.
Unloading steel wire ropes It is advisable to lift a reel by means of a shaft which
is put through its axis bore.
When handling a steel wire rope, the first trouble
often occurs immediately upon receiving it: the fork
of the fork lift truck is either placed under the reel
or inside the coil.
If outdoor storage cannot be avoided the ropes must Unwinding steel wire ropes from the reel
be covered in a way that moisture cannot create
corrosion problems. Although plastic foil protects An unreeling stand (turnable) should be used to
the ropes from rain, condensation from beneath unwind a wire rope from its reel.
might not be able to escape and could damage the
ropes permanently. To avoid condensation prob- Another accepted unreeling method is to mount the
lems, it is advisable to use breathable water-proof reel on a shaft supported by two jacks or a stand.
fabric covers readily available from tarpaulin manu-
factures.
Under no circumstances must the rope be pulled If one end of the ropes has a fitting attached, as it
off a coil while it is lying on the ground or looped is mostly the case with deck cranes, there is no
over the head of the reel, because this will inevita- other possibility than pulling the loose rope end
bly induce one torsion per wrap into the rope. through the whole reeving system.
The most advantageous way of installing a steel Below is shown an example of a typical deck crane,
wire rope varies from crane to crane. In any case a where the rope must be spooled from the reel via
procedure should be chosen that (under justifiable sheaves S1 through S9 onto the drum.
expenditure) guarentees the least risk of torsions
and avoids damage to the rope by contact with parts
of the construction.
Here, special attention must be paid to the hook tional wire ropes one must at least make sure that
block. It must be secured in an upright position so they have the same direction of lay as rope to be
that the rope can be spooled without any fleet an- installed.
gles occuring between the rope and the blocks
sheaves. If the new rope is pulled in with help of the used
one, the two rope ends are often buttwelded to-
gether. A connection of that kind can transfer the
Winding the steel wire rope from the reel twist of the old rope, built up in the reeving system,
onto the drum into the new rope. By that method of installation the
new rope may be extremely damaged.
During the manufacturing process every steel wire
rope receives its preferred bending direction when There are even more reasons why that procedure
being drawn from the wire rope closer by means of is highly problematic: It is true, that when using spe-
a capstan. When delivered to the customer the rope cial electrodes the welded connection presents
is bent in that direction. Make certain that it bends acceptable results in a pull test with a straight rope;
in the same direction when it is wound from the reel but because of the great length of rigid connection
onto the drum. zone the very same connection could break due to
the enormous bending stresses when running over
sheaves.
When installing a lang lay rope one must take care Under no circumstances should one attempt to gen-
that the Chinese finger cannot unwind from the rope erate the tensioning load by jamming the rope, for
like the nut from a screw. It is recommended to wrap instance between two boards. Structural changes
a tape around the whole rope length to be held by would deform the rope beyond repair.
the Chinese finger to increase the friction.
"Breaking-in" the steel wire rope The rope and this wire end are now wrapped mov-
ing away from the location of the intended cut.
After the rope has been installed and before it is
going to do its proper job, several run-throughs of
the normal operational circle should be carried out
under light load. The new rope
should be "broken-in", so that the
component parts can settle and
adjust themselves to the actual The rope is tightly wrapped for a distance of approx.
operating conditions. It is most un- three rope diameters.
fortunate that in practice only too
often the exact opposite of this
recommendation is performed:
quite frequently after installing the
rope overload tests are carried out
with loads beyond the safe work-
ing load of the system. Both ends of the seizing wire are then pulled tight
and twisted together for a length of one rope diam-
eter.
Cutting steel wire ropes
Quite often the lubricant is applied at a sheave, If during an inspection ends of broken wires are
sometimes a continuous drip method is used. If only detected which might cross adjacent wires and
a little lubricant is required, pressure spray nozzles destroy them when running over sheaves, these
can be applied. broken wire ends must be removed.
Maximum penetration of the lubricant into the gaps Under no circumstances should the broken wire
of the rope, can only be quaranteed if high pres- ends be pinched off with a pair of nippers. The best
sure lubrication is applied with the help of a pres- method is to move the wire ends backwards and
sure lubricator. forwards until they break deep in the valley between
two outer strands. With thicker wires a tool should
With this method the two halfs of a sleeve, which is be moved backwards and forwards on the surface
equipped with rubber sealings, are clamped round of the rope, thus bending the wires until they break.
the rope and screwed together. While the rope runs
through the lubricator the lubricant is pressed into
the sleeve at a pressure upto about 30 bars.
Severe corrosion.
Contraction rupture caused by excessive stress, Wear and identations of surface wires also promote
(e.g., if a slack line suddenly snaps taut under full fatigue and lead to premature wire rupture.
load).
Crown wires of outer strands may wear so thin that Corrosion may cause wire ropes to break. As a
the residual cross sectional area of steel in the rope safety measure, inspect ropes regularly and care-
will not support the normal design load and con- fully to prevent catastrophes; observe manufactur-
traction rupture may ensue. er's instructions
Replacement of Wires
K-Cranes
General
This instruction covers MacGREGOR K-cranes,
CARGO/GRAB CARGO/GRAB
which are equipped with limit switch boxes. The
HANDLING HANDLING
procedure is general and should be seen as a
CARGO SEP. RUN GRAB CARGO SEP. RUN GRAB
guidance. X Ton X Ton X Ton X Ton
X-Xm X-Xm X-Xm X-Xm
Replacement of closing and holding winch wire Adjustment of wires after replacement
Procedure according to paragraph "Closing and - If necessary, adjust wires.
holding winch, procedure before replacement": - Stretch up the wires on both winches. Check how
- Dismantle the wire from the grab. much is needed to be adjusted.
- Run the winch slowly by paying out the wire until - Set key switch CARGO/GRAB HANDLING in
the lowering limit switch is activated. (Empty drum, position TEST/ADJ., see Fig. 1.
holding.) - The adjustment of the wire has to be on drum.
- Mark the position of the wire drum in relation to - Adjust the angle of the grab according to
the bracket. This to avoid setting all hoisting limits instruction 6.303.35 E.
again after installing the new wire.
- Remove cover from the limit switch box. (Holding.)
Mark position
- Mark the position of the shaft in relation to the box.
Ho Limit switch box
See Fig. 5 and 6 before dividing. (Holding.) ldi
ng
- Remove the limit switch box. (Holding.) wi
nc
- Note how many revolutions of the wire there are h
Fig. 6. Limit switch box, hoisting winch. Tightening torque: In the first place look for
tightening torque on the winch spare parts picture.
In the second place see instruction 6.214 E.
Luffing winch
- Place the jib in the jib rest.
- Disengage the slack wire switch by blocking the Wire
spring tensioned roller, which can be done with a
rope, see Fig. 7.
- Loosen the wire rope end attached to the crane Rope
jib, see Fig. 10.
- Lower the wire rope to the deck by means of a
rope. Switch
- Mark the position of the wire drum in relation to the
bracket.
- Remove cover from the limit switch box.
Note! Mark the position of the shaft in relation to
the box before dividing.
- Remove the limit switch box. See Fig. 5 and 8.
- Note how many revolutions of the wire there are
left on the drum at this position. Make a mark on
the drum. Fig. 7. Disengage slack wire switch, luffing winch.
Winch drum
Limit box
Bracket
Lock washer
General
To ensure safe working conditions and long lifetime The wear, see Table 1, can certainly occur on every
of the wire rope it is important to inspect the condition spot where the wire rope is in contact with the wire
of the wire sheaves. sheave, not only on places shown in Fig. 1.
t a
max
16 3
12 3
10 2.5
8 2
6 1.5
Lifting Block/Beam
Warning!
Where equipment has swivelling and moving parts
there are potential safety hazards. Care should be
taken when working with or repairing equipment. If
used incorrectly, breakage could occur injury or
death.
General safety
Eyes for stabilizing
wires (extra equipment)
When equipment is in use, do not put hands:
1. Between sheaves, sideplates, and guards.
2. In area of hook, hook nut, and swivel.
Fig. 1. Lifting block for crane with two sheaves.
Take great care to avoid clothing becoming trapped.
Lubrication
Limitation of use
Table 1.
The initial measurements should be taken when With the jib at maximum outreach two measurements
the crane is installed at yard or within 2 months are to be taken, see Fig. 1.
from crane installation.
With the jib at minimum position one measurement is
If the wear measurement shows wear, grease samples to be taken, see Fig. 2.
can be taken for analysis.
Enclosed table can be used to record the measure-
For slewing bearing grease sampling procedure see ments.
inspection instruction 625/1651 E.
Note!
Contact Cargotec Service Organisation for exact maxi-
When measurements are to be taken the ship shall
mum slewing bearing play for your crane.
have as little list/trim as possible.
Procedure
Deviation
First time a measurement is to be taken two reference
The deviation is related to differences in production
points on the crane's bottom plate must be grinded
tolerances and material. For Cargotec a part for a more
and marked. These reference points shall then always
accurat evaluation of the bearing play.
be used at any future measuring, see Fig. 4. Write "A"
Empty hook
Measurement B Measurement A
(back of crane) (front of crane)
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
Note!
If there is a machined surface this shall be used as
reference point. In other cases a reference point must
be grinded and marked.
Jib
B,C A
Remove excessive
Reference point
wear (burr) from slew-
ing gear teeth before
measuring.
Reference point
A
B,C
Fore
Stb
Aft
Ps
Crane No.: 2
Measurement (accuracy 0.1 mm) Play Deviation Jib direction
Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C B-A
Fore
Stb
Aft
Ps
Crane No.: 3
Measurement (accuracy 0.1 mm) Play Deviation Jib direction
Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C B-A
Fore
Stb
Aft
Ps
Crane No.: 4
Measurement (accuracy 0.1 mm) Play Deviation Jib direction
Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C B-A
Fore
Stb
Aft
Ps
2011-08-18 Project No: 2/0702102LMW1
Valid for: 62507582
4 (4)
6 SERVICE
SERVICE 6.303.35 E rev.: a 2004-06-22
General
Display
Encoder 07 33 07 33 07 33 07 33 07 33
36 36 36 36 36
calibration 39 39 39 39 39
08 34 08 34 08 34 08 34 08 34
37 37 37 37 37
40 40 40 40 40
10
31
30
32
09
10
31
30
32
09
10
31
30
32
09
10
31
30
32
09
10
31
30
32
11 14 11 14 11 14 11 14 11 14
17
15
16
19
12
13
17
15
16
19
12
13
17
15
16
19
12
13
17
15
16
19
12
13
17
15
16
19
18 20 18 20 18 20 18 20 18 20
grab opening.
Example: Knob in position 50% limits grab opening
PC COM PC COM PC COM PC COM PC COM
This will continue for 10 seconds. The set calibration The display is turned off for one (1) second and then
will remain unchanged if no further calibration is mode "Po" flashes for ten (10) seconds. Do not press
choosen. Thereafter the display is turned off for 1 the "Step" pushbutton at this stage.
second and then the next calibration mode, Po, is
shown on the display. After the last calibration mode Calibration of absolute encoders, grab open (Po)
has been shown the display will return to normal view
1. Set the key switch "Cargo/grab handling" in cabin
(Sc).
to position TEST/ADJ. Turn the adjustable "Open
Grab" limit potentiometer to 100 %. Start the crane.
If a calibration is to be performed the STEP
2. Drive the crane to calibration position Po (fully
pushbutton shall be pressed when the display flashes
open), see Table 1.
with the desired calibration mode. The present grab
3. Push ENCODER CALIBRATION button in
position will be stored and the display stops flashing
CC2000 cabinet, see Fig. 2.
and lights for 5 seconds. The display is turned off for
4. Push the PROG SET button on the MPC Sc
one (1) second and continues then with the next
card front within thirty (30) seconds from pushing
programming mode.
ENCODER CALIBRATION. The display on the
"Sc" card then starts flashing showing the different
Calibration of absolute encoders, grab closed (Pc) calibrating modes: Pc and Po.
1. Set the key switch "Cargo/grab handling" in cabin 5. When the calibration mode for the motion Po (open)
to position TEST/ADJ. Turn the adjustable "Open flashes, see Fig. 2, push the Step pushbutton on
Grab" limit potentiometer to 100 %. Start the crane. MPC card Sc and the value is stored (the display
2. Drive the crane to calibration position Pc (closed), stops flashing and lights for five (5) seconds).
see Table 1.
3. Push ENCODER CALIBRATION button in
CC2000 cabinet, see Fig. 2.
4. Push the PROG SET button on the MPC Sc
card front (within thirty (30) seconds from pushing
ENCODER CALIBRATION). The display on the
"Sc" card then starts flashing showing the different
calibrating modes: Pc and Po.
5. When the calibration mode for the motion Pc
(closed) flashes, see Fig. 2, push the Step
pushbutton on MPC card Sc and the value is sto-
red (the display stops flashing and lights for five
(5) seconds).
Encoder 07 33 07 33 07 33 07 33 07 33
36 36 36 36 36
calibration 39 39 39 39 39
08 34 08 34 08 34 08 34 08 34
37 37 37 37 37
40 40 40 40 40
10
31
30
32
09
10
31
30
32
09
10
31
30
32
09
10
31
30
32
09
10
31
30
32
- Stepless adjustable "open grab" software limit.
11
12
13
14
15
16
11
12
13
14
15
16
11
12
13
14
15
16
11
12
13
14
15
16
11
12
13
14
15
16
17 19 17 19 17 19 17 19 17 19
TX
42
20
28
18
TX
42
20
28
18
TX
42
20
28
18
TX
42
20
28
18
TX
42
20
28
grab opening.
Contents
1. Description of input and output signals ............................................................................................... 2
2. Control system input and output signal levels ..................................................................................... 5
3. Signals indicated on the MPC card front panels ............................................................................... 10
4. Troubleshooting the control system ................................................................................................... 13
5. Operating the crane with broken MPC cards .................................................................................... 20
6. Spare parts ....................................................................................................................................... 20
1.1 General
The following description refers to the microcomputer
based crane control system CC2000 for MacGREGOR
Cranes hydraulic deck cranes, single crane versions.
1.2 Power supply, control system 1.3 Power supply, control system anti-
operation condensation heating
The power supply transforms the input 380/400/440V The anti-condensation heating in CT2 cabinet is
AC to 24V and 8V DC. See Fig. 1. powered with 24V AC when the control system is
switched off or when the crane is not in operation. A
It consists mainly of a three phase transformer, separate transformer is used for all anti-
rectifier bridges and fuses. The output 24V DC is condensation heating in the crane. The transformer
used for the control system input and output signals. is fed by a separate power line.
The 8V DC is used by each MPC card to generate
5V DC for its microprocessor.
1.4 Control lever (joystick)
The output voltage has a ripple with 6 times the The right control lever controls the hoisting winches,
frequency of the input power line. The ripple level is holding and closing. Both digital and analogue sign-
approx. 15%. als from the joystick are connected to the MPC card
"Ho" for holding and MPC card "CL" for closing.
The 0V level for 24V DC is grounded in the power The left control lever controls the luffing and slewing
supply unit and the 0V for 8V is grounded via all four movements.
MPC cards in CT2 cabinet.
1.4.2 Control levers direction signal Each MPC card is capable of controlling a maxi-
inputs mum of three pumps with a total of six output
drivers, one for each solenoid valve. Each driver is
The control lever for hoisting selects one out of four
capable of outputting a maximum current of 1A. To
24V direction signals, hoisting/lowering/closing/
measure the current without opening the circuit, a
opening. See Fig. 2.
measuring point is available for each pump. Using
a voltmeter, the reading in mV equals the current in
The control lever for luffing/slewing gives two out of
mA to within approx. 5%.
four 24V direction signals for selecting luffing in/
luffing out and slewing left/slewing right.
CT2
1.8 Brake release/direction valve outputs 1.12 Lamp output "Error in control
Each MPC card having an output driver for the
system"
brake release signal (or direction valve for cranes All error LEDs (No. 28) on the MPC cards are wired
equipped with cylinder luffing). The system is together to a lamp in the crane operator's cabin.
capable of detecting short-circuited output and then When an error first occurs the lamp flashes. When
giving an error-message, see ERROR MESSAGES the error is acknowledged by pushing the STEP
sign. push-button on the appropriate MPC card, the lamp
is on if the error remains or out if the error is not
1.9 Displacement/unloading outputs present for the moment. See sign ERROR
MESSAGES for detailed information about error
Each MPC card having two separate outputs. They messages.
are used for selecting low speed or high speed for
the holding and closing winches and for the
unloading function for the luffing movement. Each
output gives a fixed 24V output with a maximum
current of 2A.
Control system interface signal Plinth No. MPC card Signal level
Power for microprocessors on MPC 58 (with fuse) All +8V, nominally 9V,
cards minimum 7V.
54 0V.
Control lever direction inputs hoisting 24V when control lever actuated
Hoisting 207 Ho Hoisting
Lowering 208 Ho Lowering
Control lever potentiometer input sig- 404 Analogue input signal 1.5 to
nal slewing 10.5V with 6V in neutral
position.
Control system interface signal Plinth No. MPC card Signal level
Control lever direction inputs slewing 24V when control lever actuated
Slewing left 407 SL Slewing left
Slewing right 408 SL Slewing right
Control lever potentiometer input signal 504 CL Analogue input signal 1.5 to
closing 10.5V with 6V in neutral
position.
Control lever direction inputs closing 24V when control lever actuated
Closing 507 CL Slewing left
Opening 508 CL Slewing right
Holding/Closing displacement low 231/531 Ho/CL 24V, max. 2A, open and short
speed output circuit gives error message.
Holding/Closing displacement output 232/532 Ho/CL 24V, max. 2A, open and short
high speed circuit gives error message.
Luffing unloading output 331 Lu 24V, max. 2A, open and short
circuit gives error message.
Pump PWM signals for holding pump2 24V, 0 to approx. 600 mA,
(if fitted) Error message if desired
Hoisting output 236 Ho current not achieved.
Lowering output 237 Ho 1mA gives approx. 1mV.
Current return and current measured 238 Ho
input
Pump PWM signals for luffing pump1 24V, 0 to approx. 600 mA,
Luffing in output 333 Lu Error message if desired
Luffing out output 334 Lu current not achieved.
Current return and current measured 335 Lu 1mA gives approx. 1mV.
input
Control system interface signal Plinth No. MPC card Signal level
Pump PWM signals for slewing pump1 24V, 0 to approx. 600 mA,
Slewing Left output 433 SL Error message if desired
Slewing Right output 434 SL current not achieved.
Current return and current measured input 435 SL 1mA gives approx. 1mV.
Pump PWM signals for Closing pump1 24V, 0 to approx. 600 mA,
Hoisting output 533 CL Error message if desired
Lowering output 534 CL current not achieved.
Current return and current measured input 535 CL 1mA gives approx. 1mV.
Pump PWM signals for Closing pump2 24V, 0 to approx. 600 mA,
(if fitted) Error message if desired
Hoisting output 536 CL current not achieved.
Lowering output 537 CL 1mA gives approx. 1mV.
Current return and current measured input 538 CL
Control system interface signal Plinth No. MPC card Signal level
Pressure switch input for low feed 219 Ho 24V at normal operation,
pressure 319 Lu 0V at low feed pressure.
419 SL
519 CL
Output for "Speed dependent 229 Ho 24V when the hoisting speed
overload" function (if fitted). is less than approx. 3 rpm.
Speed reduction, input signal ext. 1 217 Ho 24V input from cabin switch,
(bit 0) to reduce normal operation 317 Lu such as grab operation,
speed (utilization). 417 SL parking lock slewing, power
517 CL limiter, twin operation, etc.
Speed reduction, input signal ext. 2 218 Ho 24V input from cabin switch,
(bit 1) to reduce normal operation 318 Lu same as above.
speed (utilization). Same as above, 418 SL
but could be used with different 518 CL
utilization.
Auto closing, enabled (if fitted) 111 Sc 24V input when activated
Control system interface signal Plinth No. MPC card Signal level
Remote In Ground
Supervisor 125 Sc Ground reference for Remote
Holding 225 Ho In signal (0 Volt)
Luffing 325 Lu
Slewing 425 SL
Closing 525 CL
- Green is used for normal inputs and outputs. When an input LED is on, that signal has passed the
- Yellow indicates that the crane motion concerned optoisolated 24V to 5V conversion and reached the
is driven at slower speed. microprocessor.
- Red indicates that the motion has been stopped.
When an output LED is on, the microprocessor
Normal operation green signals are shown with outputs the signal at 5V level, but it has not yet
inputs to the left and the corresponding outputs to passed the 5V to 24V output driver stages. Check
the right of the input. They are on when the signal is the signal output level on the corresponding plinth if
active, 24V. missing output is suspected.
Speed reducing limit switches are shown with yellow 3.3 Identifying the plinth number
LEDs when the 24V signal is absent. Speed corresponding to an LED
reduction inputs from key switches are shown with
The plinth number is identified by a three-digit
yellow LEDs when the input is active, 24V.
number. The first digit of each number signifies the
MPC card to which the signal is connected:
Stop limit switches, low feed pressure and overload
1.. Supervisory MPC card, "Sc".
are indicated by red LEDs when the 24V signal is
2.. Hoisting MPC card, "Ho".
absent.
3.. Luffing MPC card, "Lu".
4.. Slewing MPC card, "SL".
On the "Sc"- card signals for Cargo/Grab operation
5.. Closing MPC card, "CL".
mode selection (and other operation mode selector
inputs, if fitted) are indicated with yellow LEDs.
The last two digits signify the LED number on each
MPC card front panel, showing the status of the 24V
All signals indicated by LEDs are listed on the
input and output signals for the card. The same two-
SIGNAL OVERVIEW sign inside CT2 cabinet (MB),
digit number is used on the cables from the plinth to
see section "Service", Group 6.3.
each MPC card.
MPC "Sc" MPC "Ho" MPC "Lu" MPC "SL" MPC "CL"
Input Output Input Output Input Output Input Output Input Output
17 32
(grab (hydr. circ
operation) connected)
42 42 42 42 42
(+24V) (+24V) (+24V) (+24V) (+24V)
Tx Tx Tx Tx Tx
Table 1. MPC card readouts for idling crane with Grab closed.
MPC "Sc" MPC "Ho" MPC "Lu" MPC "SL" MPC "CL"
Input Output Input Output Input Output Input Output Input Output
36 07 33 07 33 07 33 33
(grab (hoisting) (hoisting (luffing in) (luffing in (slewing (slewing (hoisting
closed) pump1) pump1) left) left pump1)
pump1)
17 32 31 31 31
(grab (hydr. circ (low speed) (unloading) (low speed)
operation) connected) 30 (brake) 30 (brake) 30 (brake) 30 (brake)
42 42 42 42 42
(+24V) (+24V) (+24V) (+24V) (+24V)
Tx Tx Tx Tx Tx
Table 2. MPC card readouts when hoisting, luffing in and slewing left with closed Grab.
4.1 General
This section provides information for identifying and When troubleshooting a malfunction: locate the
correcting malfunctions which may develop while symptom or symptoms that best describe the
operating the Crane. Before performing malfunction. If the appropriate symptom is not listed,
troubleshooting, read and follow all safety instructions notify your supervisor.
found in section "General", Group 1, of this manual.
This chapter cannot list all malfunctions that may Perform each step in the order listed until the
occur, nor all inspections and corrective actions. If a malfunction is corrected.
malfunction is not listed, or is not corrected by the
listed corrective actions, notify your supervisor. Note!
Read this section in conjunction with the
Ensure that the crane movement has not stopped electrical and hydraulic diagrams provided
because of overload. in Group 9.5 and 9.4.
Both lamps One or both lamps are Check the error code in
are off. flashing or on. Control System cabinet ,
see chapter 4. 5.
4.3 Checking Power supply 24 V and 8 V 4.4.4 Check pump servo valves
DC in CT2 cabinet
(See chapter 1.2. for explanation of the power - Check valves 1111-9, 1112-9, 1113-9, 1114-9,
supply function.) 2111-9, 2112-9, 2113-9, 2114-9, 3111-9, 3112-9,
Check over-current relay Q3 in cabinet CT1. 3113-9, 3114-9.
Check fuse for 8 V in terminal 58 in CT2 cabinet. - Check electric cable connections
Check wall-mounted rectifier unit in cabinet CT1
(cabinet CE) fuses, 1 to 6 inclusive, for trans-
former T1 in CT1 cabinet (cabinet CE). 4.5 How to obtain error codes from the
Check relay K34 in cabinet CT1, see Circuit CC2000 system
Diagram Crane
The CC2000 system has an inbuilt diagnostics
No LED and display readout on MPC card
system able to detect several types of malfunction
indicates missing 8V.
of the CC2000 system itself and its peripheral
devices, i.e. power supply, joystick, pump servo,
4.4 Checking Limit switches, Joysticks
hydraulic valves, sensors and communication lines.
and Electro-Hydraulic Interfaces
When the CC2000 Control System Error lamp in
4.4.1 Check Limit Switches, see Control system the drivers cabin flashes and the crane is still
in CT2 cabinet running, the following steps are necessary to obtain
(See chapter 3 for explanation of signal indication the error code(s).
LEDs.) - Open the control system cabinet CT2 and look for
No LEDs on and no display readout - indicates
the card with flashing LED 28.
missing 8V, see chapter 4.3.
Check for Red LEDs - indicating stop limits. - Push the STEP button on that card. A two-digit
Check for Yellow LEDs - indicating speed reduces. error code is shown on the display of the card.
Check electric cable connections for limit Continue pressing STEP for further error codes.
switches. When there are no more error codes, the display
For checking and adjustment of limit switches shows two hyphens . The error LED is now
see instruction for Limit Switches in Service
either on or off.
Group 6.
6. Spare parts
6.1 MPC card, 314 3603-8xx
The ready-to-use MPC card, no. 314 3603-8xx,
(where -8xx means anyone of -801, -802, -803 etc.)
consists of a hardware electronic card loaded with Memory Card 314 3605-801
software. For correct article no., see spare parts consists of
list, section 9.5.
Hardware: 314 3605-901
Software: 6250xxxx
When ordering an MPC card without knowing the
article no. (-8xx), specify the software version
needed and proceed as follows.
LEDs
24V Input and Output signals are indicated with coloured LEDs. Hardware
314 3603-902
Hardware
314 3603-902
Hardware
314 3603-902
Hardware
314 3603-902
Hardware
314 3603-902
17,18 08
39
34 08
39
34 08
39
34 08
39
34 08
39
34
and overload 09 31
30
09 31
30
09 31
30
09 31
30
09 31
30
10 32 10 32 10 32 10 32 10 32
TX 28 TX 28 TX 28 TX 28 TX 28
42 42 42 42 42
Plinth number
Combine card no with LED no 3 1 9
Slip-ring unit
Danger!
Before opening the slip-ring unit, make sure that
power supplied by separate transformers is switched
off in the ship's engine room. Also check by means
of a voltmeter that the slip-ring unit is not alive.
Oil thermostats
BT 2
The task of the oil thermostat is to protect the crane
against overheating.
BT 3 (Optional)
The task of the thermostat is to start the oil cooler when
the oil reaches +45oC when crane is set to winter posi-
tion.
DANGER!
Before opening the slip-ring unit, make sure that pow- The function of the slip-ring assembly may not be
er supplied by separate transformers is switched off changed in any way. Especially safety devices must
in the ship's engine room. Also check by means of a not be made ineffective. Other than during mainte-
voltmeter that the slip-ring unit is not alive. Make sure nance and inspection work the housing must always
that the current can not be switched on again during remain closed.
the maintenance operation.
Use only insulated tools and original spare parts.
Work on a slip-ring assembly may only be carried out No responsibility will be assumed for damage to prop-
by a qualified electrician or by persons under the su- erty or injury to persons caused by improper use of
pervision of a qualified electrician and only according the slip-ring assembly.
to accepted electrical safety procedures.
Assembly screws
Rubber protection
Note!
Must be tightened.
Maintenance
Removal
Always cut current before accessing the collector for
1. Park the jib in a suitable manner. inspection or maintenance. Make sure that the current
2. Disconnect the ship's power supply at all points can not be switched on again during the maintenance
of feed. operation.
3. Disconnect all the cables connection from cranes-
and ship supply.
At regular intervals
4. Remove the driver connecting the slip-ring unit and
- Check collector for damaged parts
the foundation. Note the cables mounting sequence.
- Check contact pressure of brushes
5. Remove the mounting screw holding the slip-
- Check brush holders
ring unit on the eccentric platform bottom plate.
See Fig. 1.
6. Remove the slip-ring unit. Carbon brushes
- The carbon brushes must never wear down so
Any extra equipment such as extra limit switches fitted far that metal parts of the brush holder come into
on top of the slip-ring unit are removed prior to removal contact with the slip-ring.
of the entire slip-ring unit.
The carbon dust is to be removed with dry, oil free,
Installation compressed air or with a vacuum cleaner.
No substance containing oil or grease may come
Clean all contact surfaces between slip-ring unit and into contact with the brushes or the slip-rings.
cranehouse bottom. Tighten all screws properly. See
instruction "Tightening torque".
Wire brushes
- Check wire brushes.
1. Assemble the slip-ring unit under the eccentric
Debris caused by wear is to be removed with dry,
platform bottom.
oil free, compressed air or with a vacuum cleaner.
2. Assemble the driver to the bottom of the foundation
Afterwards the slip-ring ways and wire brushes
3. Remove the cover around the slip-ring unit
should be lightly sprayed with "Cramolin B" or
4. Fit the slip-ring unit guide pins to the driver's slotted
equivalent contact spray.
holes by pulling apart the driver and lock it with help
of the through bolt
5. Install the cables against the driving bar Others
6. Connect the crane cables from the eccentric plat- - Check tightness of electric and mechanical fasten-
form on correct mounting sequence ers.
7. Remove the connection box plates - Check gaskets and cable glands for tightness.
8. Connect the cables to the plinths
Keep grease and oil products away from the plastic
insulating parts in the collector.
After installation
- Check tightness of all electric and mechanical
fasteners regularly for the first working period.
- Check alignment. The slip-ring unit must not be
allowed to slope in relation to the driver.
- Rotate the eccentric platform to ensure that no
mechanical side forces are transferred to the unit.
- Tighten the rubber protection , see Fig. 1.
Slip-Ring Unit
Work on a slip-ring assembly may only be carried No responsibility will be assumed for damage to
out by a qualified electrician or by persons under property or injury to persons caused by improper
the supervision of a qualified electrician and only use of the slip-ring assembly.
according to accepted electrical safety procedures.
Mounting screws
Connection crane
Rubber protection
Note! Must be
tightened.
Removal Maintenance
1. Park the jib in a suitable manner. Always cut current before accessing the collector
2. Disconnect the ship's power supply at all points for inspection or maintenance. Make sure that the
of feed. current can not be switched on again during the
3. Disconnect all the cables connection from crane- maintenance operation.
and ship supply.
4. Remove the driver connecting the slip-ring unit
At regular intervals
and the foundation. Note the cables mounting
- Check collector for damaged parts
sequence.
- Check contact pressure of brushes
5. Remove mounting screw holding the slip-ring unit
- Check brush holders
on crane house bottom. See Fig. 1.
6. Remove the slip-ring unit.
Carbon brushes
Any extra equipment such as extra limit switches - The carbon brushes must never wear down so
fitted on top of the slip-ring unit are removed prior far that metal parts of the brush holder come into
to removal of the entire slip-ring unit. contact with the slip-ring.
The carbon dust is to be removed with dry, oil
free, compressed air or with a vacuum cleaner.
Installation No substance containing oil or grease may come
into contact with the brushes or the slip-rings.
Clean all contact surfaces between slip-ring unit
and cranehouse bottom. Tighten all screws prop-
Wire brushes
erly. See instruction "Tightening torque".
- Check wire brushes.
Debris caused by wear is to be removed with dry,
- Assemble the slip-ring unit under crane bottom
oil free, compressed air or with a vacuum cleaner.
- Assemble the driver to the bottom of the founda-
Afterwards the slip-ring ways and wire brushes
tion
should be lightly sprayed with "Cramolin B" or
- Remove the cover around the slip-ring unit
equivalent contact spray.
- Fit the slip-ring unit guide pins to the driver's slot-
ted holes by pulling apart the driver and lock it
with help of the through bolt Others
- Install the cables against the driving bar - Check tightness of electric and mechanical
- Connect the crane cables from the crane on cor- fasteners.
rect mounting sequence - Check gaskets and cable glands for tightness.
- Remove the connection box plates
- Connect the cables to the plinths Keep grease and oil products away from the plastic
insulating parts in the collector.
After installation
- Check tightness of all electric and mechanical
fasteners regularly for the first working period.
- Check alignment. The slip-ring unit must not be
allowed to slope in relation to the driver.
- Rotate the crane ensure that no mechanical side
forces are transferred to the unit.
- Tighten the rubber protection , see Fig. 1.
Introduction
To prevent operation of the crane with too little oil in
the hydraulic oil tank, an oil level guard is installed in
the oil tank, see Fig. 1. The level float switch controls LOW OIL LEVEL
an indicator light on the control panel and a siren. A
FLOAT SWITCH key switch is placed on the control
panel to select different modes depending on oil level
in the hydraulic oil tank.
See Fig. 2.
FLOAT SWITCH
NORMAL
SIREN BY
OFF PASS
Float
MAX
Oil level MIN LOW OIL LEVEL FLOAT SWITCH
NORMAL
If the oil level drops to MIN, the float activates the SIREN BY -
OFF PASS
upper switch and indicator light "LOW OIL LEVEL" MIN
comes on and the siren sounds. See Fig. 4.
Note!
Operating crane when oil level is below MIN can cause
Fig. 5. Oil level MIN, continued operation.
damage to crane equipment.
NORMAL
below MIN level, the float activates the lower switch SIREN BY-
OFF PASS
and stops the crane. The "LOW OIL LEVEL" indicator MIN
light stays on. See Fig. 6.
tor light "LOW OIL LEVEL" comes on and the siren NORMAL
SIREN BY-
sounds. This is permitted if no important leakage is MIN OFF PASS
Overheating protector
The crane stops automatically when the oil tempera-
ture exceeds 85C. The overheating protector is fitted
on the inlet line of the oil cooler. An indicator light
"HIGH OIL TEMP" comes on when the oil temperature
is more than +85C. See Fig. 8.
General
The limit switch boxes of the hoisting and luffing Limit switch,
winches are similar except for the demultiplication closing winch
ratios of their driving gearboxes.
Fig. 1. Limit switch boxes in crane house.
CAUTION!
Back off the lockscrews of the switch cams in the Please note that the Jib radius measures refer to
limit switch boxes, using a 10 mm articulated the crane house slewing centre (Not to the jib
wrench; the cams are then easily rotated to their bearing centre!). The measures H and K refer to
proper settings. the jib bearing centre.
After setting the cams correctly, retighten the lock- Jib radius, Max. (m)
screws and operate all crane movements, Jib radius, Min. (m)
beginning at reduced speed and finishing at Jib radius, High hook (m)
maximum speed to check cam settings.
Lifting height, H (m)
Lifting height, K (m)
Lifting height, High hook (m)
Measure line
5 Adjustment
screw
H
30 55
K
H
Jib radius
Lock screw
K
Jib
Fig. 2. Cam. radius
5
Measure line Measure line
Adjustment Adjustment
screws screws
100 245
Lock screw
Fig. 3. Cam.
BL1
BL2
BL3
BL4
BL5
(BL6)
(BL7)
Stop.
Raise the jib into its upper position, MIN jib radius
position, which is the correct position for setting the
limit switch, i.e. the K-measure. (Lowest point, BH1,
of the holding winch.)
To set the limit switch BH4 to its highest point, i.e. BH1
the H-measure, the jib must be in MIN jib radius BH2
position. BH3
BH4
Note that switches BH2 and BH3 actuate speed (BH5)
reduction of the grab. (BH6)
Limit switches Degrees Remarks
holding winch Angular
BH1 10 indicator
BH2 40
BH3 40 Fig. 7. Limit switch box on holding winch.
BH4 10
BH5 - Spare
BH6 - Spare
BH3
H = 0.0 m (grab)
Min. R
K = 36.0 m (grab)
BH2
Approx. 2.5 m
BH1 Empty drum limit, stop position
(At least three locking turns or
tank top.)
= Reduced speed
*)
*)
*)
*)
Note!
In a certain area there is a possibility that hook block The cranes are designed, calculated and manufac-
and jib top will meet. See Figs. 11 and 12. This will tured in accordance with and approved by classifi-
not cause any problem as the cranes safety system cation societies.
takes care of it.
A slacking luffing or hoisting wire rope should stop
It is only possible for the hook block to reach jib top the luffing out and hoisting movements by use of
at large outreaches. the slack wire switch BWL1.
The hook block and the crane jib is designed and Hook block hoisting the jib:
calculated to take care of the forces which occur - This actuates the slack wire switch BWL1 and
when the hook block is hoisting the jib top or the jib the hoisting movement stops.
top lands on the hook block.
Jib landed on the hook block:
At small outreaches the full drum limit, BH4, on - Luffing wire slackens and the slack wire switch
the drum will be in operation. BWL1 actuates. The luffing out movement stops.
Wire rope
Support
Support
Switch
Switch
Slack wire switch, luffing. Normal condtion. Slack wire switch, luffing. Slack wire condtion.
Introduction CAUTION!
- This work has to be done with great caution by
In the case of a power failure the hoisting, luffing skilled persons.
and slewing circuits of a deck crane may still be - Only one function to be activated at the time.
operated to a limited extent by releasing their re- - Verify that no persons are within the working area
spective brakes, while observing the greatest care. of the crane.
- Valves 1247, 1248, 2661 and 3661 must not be
The release of the brakes of the hoisting, luffing, actuated except in emergency brake release op-
and slewing functions is facilitated by employing an eration.
electric pump designed for this purpose, a quick cou-
pling and a shut-off valve is also installed.
Manometer 1D
Electric pump
Restriction unit
3A 3B 3A 3B
Plug
Connection to 1144-A1
and 2141-B
Connection to quick coupling
1664 and 1665
By-pass line
Check-restriction
valve
Plug
Screw
Plug
3A, 3B
Hydraulic
motor
Manometer 1D
Emergency Electric
stop valve 1C pump
4333
4332
Oil tank
Pipe coupling
Pressure relief
valve 1B Connection
to tank
Connection to
quick coupling
1664 and 1665
After operation
After the emergency lowering operation is
completed, reset the crane to NO EMERGENCY
COUPLED and close valve 4332 and open valves
1247 and 1248. See Fig. 5.
Check once again that the pilot hoses are correctly
mounted to 1127-2 and 1128-2 (connection A1 and
B1).
1127-1
1128-1
P
By-pass line
By-pass line
Control pressure
Feed pressure in
Feed pressure out
Function
The emergency lowering system means that the
motor hydraulically controls the jib. Electric pump
1A puts pressure on the low side of the motor (A-
side) and on the brake 2211 which opens at approx.
12-15 bar (1D).
Screw
Bushing
Valve unit
Check-restriction valve
Plug
Emergency stop valve 1C
Manometer 1D
Quick coupling 4333
Electric pump Valve 4332
Oil tank
Pressure
relief valve 1B
Connection to quick
coupling 2664
Connection to tank
Connection
- Place the electric pump in front of the oil tank. The connection between the A-side and the brake
- Disconnect the hydraulic hose at hydraulic motor is a very important safety function against
2141-B. uncontrolled lowering.
- Connect the hoses from the electric pump to quick
coupling 2664 and 2141-B as shown in Fig. 8 and Caution!
10. One person must all the time during the emergency
- Disconnect the pilot hose and check-restriction lowering keep the emergency stop valve 1C pressed
valve 2241-1 from connection P, valve 2127. Plug down. If unpredictable problems appear, the
the disconnected hose by using plug M22 x 1.5. emergency stop valve 1C must at once be released
See Fig. 8, 9 and 10. and the brake will then quickly close.
- Attach bushing and screw into connection P,
valve 2127. Screw home the threaded up to the After operation
neck screw to actuate the piston to blocked po-
After the lowering operation is completed, reset the
sition. See Fig. 9 and 10.
crane to NO EMERGENCY COUPLED. Valve
- Close valve 2661 and open valve 4332, see Fig.
4332 must be closed and valve 2661 must be open.
8 and 10.
See Fig. 11.
- Connect suction hose to quick coupling 4333.
Check once again that the pilot hose is correctly
Open valve 4332. See Fig. 8.
mounted to 2141-B.
Caution!
It is of most importance that hoses from electric
pump are correctly mounted to 2664 and 2141-B.
See Fig. 8.
Operation
- Close restriction valve 3B.
- Open pressure relief valve 1B.
- Start the electric pump 1A.
- Press down emergency stop valve 1C and slowly
increase pressure with pressure relief valve 1B.
Leakage inside pump and motor causes that jib
is slowly lowered.
- If the jib lowering speed is too low open restriction
valve 3B.
Feed pressure in
Feed pressure out
Drain
Flushing pressure
Control pressure
Feed pressure in
Feed pressure out
Drain
Flushing pressure
Control pressure
Slewing circuit
Function
The brake of the slewing gears are opened with Note: The brake opens at approx. 12 bar.
pressure from the electric pump. The crane without
tilt or trim may then be turned to a new position with Warning!
the help of another crane or winch. A crane with tilt
If the crane is tilted, the brake must be released
or trim has to be turned with great caution.
with great caution. If the speed tends to accelerate
too much, the brake can be activated by opening
Connection emergency stop valve 1C.
- Place the elctric pump in front of the oil tank, see
Fig. 12. After operation
- Connect the hose from the electric pump to quick
After the slewing operation is completed reset the
coupling at 3664 as shown in Fig. 12 and 13.
crane to NO EMERGENCY COUPLED. Valve 4332
- Close valve 3661 and open valve 4332, see Fig.
must be closed and valve 3661 must be opened,
12 and 13.
see Fig. 14.
- Connect suction hose to quick coupling 4333. Open
valve 4332. See Fig. 12.
Operation
- Open pressure relief valve 1B.
- Start the electric pump.
- Press down the emergency stop valve 1C and
slowly increase the pressure until brakes are
open by closing valve 1B.
3664
3661
Emergency stop
valve 1C
Manometer 1D 4332
4333
Feed pressure in
Feed pressure out
Drain
Flushing pressure
Control pressure
Feed pressure in
Feed pressure out
Drain
Flushing pressure
Control pressure
General
MacHeavyvisor is a computer program that is part MacHeavyvisor has two main purposes:
of the logging and information system delivered by
- Displaying real time information about current
MacGREGOR Cranes. The program is executed
properties of the crane such as jib radius, load
on a dedicated computer installed inside the crane
in the hook, hoisting speed, list and trim. There
cab. MacHeavyvisor communicates with crane
can also be additional information such as Anti-
control system (CC2000) via data communication
collision and twin cranes.
cable. The MacHeavyvisor program and the
computer is automatically started and stopped
- Logging information about crane operations,
when the electric power of the crane system is
allowing future analysis.
switched on/off.
Main screen
The main screen is the default view of the
application and also the one first visible when the SINGLE MODE or for standard cranes it might
application starts. also be empty.
communication on both serial ports connected to the parameters these fields can be available: Max
the CC2000-systems (one or two). The first is the List, Max Trim, High Pressure, Min Feed Pressure,
top square and the second one is below. Max Crane Temp, Min Crane Temp, Max Oil Temp
and Min Oil Temp.
Everything sent/received on these ports is
displayed in this window, not just information
intended for the application. The numbers in
square brackets (example: [485]-> ) is the time it
took in milliseconds to receive or send the data.
The pause button stops the automatic update of
the window.
Reason
To avoid damaging the CPU-unit, the power supply has to be turned off. As this unit is
connected to a separate power supply it is not enough to turn off the crane.
F6
USER MANUAL
DISPLAY
CC Pilot XS
1 COMPATIBILITY .............................................................................................................................................. 2
1 Compatibility
The display is compatible with Windows CE and Linux.
4 Code data
Device's code data is placed at the back of the unit.
Code data are important from the service point of view, and so beware from disposing those.
If the display would not work correct, please contact MacGREGOR, Service Department, rnskldsvik,
Sweden.
6 Display unit
X1
1 X2
2 X8
3
4 X5
5
X9
X6
The display screen has 10.4 LCD TFT display with a touch screen.
6.1 Buttons:
1. Power button can be used to turn on/off the unit. If pressed for a long time, there will be a
forced power off.
2. Increase brightness.
3. Decrease brightness.
6.2 LEDs:
4. Red LED that blinks at start up.
5. Light detector of automatic brightness adjustment.
6.3 Connectors:
X1 Power
X2 Ethernet1
X5 Misc (Used as Serial communication port)
X6 CAN1
X8 USB1
X9 USB2
7 Start up
The display starts up at the same time as the crane. First it loads the operating system and after that
the display starts the program. When starting, screen is black and the red LED is blinking.
8 Problem solving
If there are some problem with the display check the following first, then call MacGREGOR Service Department.
8.1 The display is dark or dim when crane is working
Check the brightness adjustment of the screen.
Check cables and connectors to the display unit.
Push the power on button on the display unit.
8.2 Communication faults
Check that the cables are properly connected.
8.3 LED is blinking red but program does not start
Try to switch off the unit and start again with the power button.
9 Technical Data
This display is especially developed for use of heavy machinery, which guarantees system durability and flexible
expandability to the different applications.
Kernel Power
Processor Intel XScale, 533 MHz Voltage 10 - 36 VDC
Compact Flash 32 MB -> commercially available Current < 500 mA at 24 VDC (6.5)
Kernel Flash 32/ 64 MB Environment
RAM -> 256 MB SDRAM IP-class IP65
Graphic controller Silicon motion, 8 MB RAM Temperature range -40 C - +65 C (operating)
Interfaces -40 C - +70 C (storage)
2 x CAN 2.0B, ISO 11898 24V,1 Mbit EMC conformity In accordance with 89/336/EEC:
2 x Ethernet 10/100 Base-T EN 50081-2: 1993
2 x USB 2.0 Software
RS232 OPTION. 115000 baud, replaces Operating system: Windows CE 5.0
Keyboard & Mouse Via USB Internal control
Display Status LED In front panel
10.4 SVGA 800x600 TFT Photo diode Automatic backlight control
Backlight CCFL ~400 nit Internal temperature protection against overheating
Touch screen Resistive in abnormal ambient conditions.
Mechanical
Enclosure Aluminum Dimensions
Mounting Stand Screen size: 10.4
Connectors DIN M12 Depth: 40 mm
Height: 217 mm
Width: 285 mm
9 SPARE PARTS
9.0 HOW TO ORDER SPARE PARTS......................................................................... 9-1
How to order spare parts - 6.000 E, IPD.................................................................. 9-1
9.1 MACHINERY........................................................................................................... 9-2
Hoisting winch - 189 6281-801, IPD........................................................................ 9-4
Pendulum carrier. complete - 875 13041-004, IPD.................................................. 9-8
Drive in. complete - 875 13004-121, IPD............................................................... 9-10
Drive in. complete - 875 13004-122, IPD............................................................... 9-12
Gear. complete - 875 13019-068, IPD................................................................... 9-14
Gear. complete - 875 13019-069, IPD................................................................... 9-16
Pressure roller. complete - 875 13030-007, IPD.................................................... 9-18
Oil pipe. complete - 875 13009-093, IPD............................................................... 9-20
Hydraulic motor - 188 1773-801, IPD.................................................................... 9-22
Hydraulic motor - 188 1222-801, IPD.................................................................... 9-24
Luffing winch. mount - 289 2750-801, IPD............................................................. 9-26
Luffing winch - 189 3479-801, IPD......................................................................... 9-28
Drive in. complete - 875 13004-083, IPD............................................................... 9-30
Gear. complete - 875 13019-076, IPD................................................................... 9-32
Flange. complete - 875 13021-027, IPD................................................................ 9-34
Oil pipe. complete - 875 13009-061, IPD............................................................... 9-36
Hydraulic motor - 188 1221-801, IPD.................................................................... 9-38
Winch mounting set - 289 2723-801, IPD.............................................................. 9-40
Winch mounting set - 289 2724-801, IPD.............................................................. 9-42
Slewing gear assembly - 391 0279-801, IPD......................................................... 9-44
Slewing gear assembly set - 391 0247-801, IPD................................................... 9-46
Slewing gear mounting - 391 0280-801, IPD......................................................... 9-48
Slewing gear - 289 1547-801, IPD......................................................................... 9-50
Slewing gear - 289 3838-801, IPD......................................................................... 9-52
Drive in. complete - 875 13004-096, IPD............................................................... 9-54
Hydraulic motor - 188 1223-801, IPD.................................................................... 9-56
Hydraulic motor - 188 1774-801, IPD.................................................................... 9-58
Slewing gear adapter - 389 4205-801, IPD............................................................ 9-60
9.2 PUMP UNIT OIL COOLER................................................................................... 9-62
Pump drive - 187 9744-801, IPD........................................................................... 9-64
Pump unit - 189 4717-801, IPD............................................................................. 9-66
Pump unit - 189 5452-801, IPD............................................................................. 9-68
Pump unit - 189 5690-801, IPD............................................................................. 9-70
Gear box - 390 6524-801, IPD............................................................................... 9-72
Hydraulic pump - 289 1833-801, IPD..................................................................... 9-74
Hydraulic pump - 289 1834-801, IPD..................................................................... 9-76
Pump - 289 4534-801, IPD.................................................................................... 9-78
Pump - 289 4533-801, IPD.................................................................................... 9-80
9 SPARE PARTS
How to order spare parts 6.000 E, IPD
Item Qty Unit Part number Description See
page
000 6.000 E 6.000 e
References
6000
Figure 1. 6251450135B
References
Figure 2. 6251451140
Figure 3. 6251451139
Figure 4. 6251451142
Figure 5. 6251451036
Figure 6. 6251451037
Figure 7. 6251451039
Figure 8. 6251451141A
Figure 9. 6252205014
References
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